Factory Workshop Manual
Make
Chevrolet
Model
Impala
Engine and year
V8-5.3L (2008)
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This manual was submitted by
Anonymous
Date
1st January 2018
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations > Page 10
Alarm Module: Diagrams
Component Connector End Views - Continued
Theft Deterrent Module (TDM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent (CTD) Does Not
Disarm with Key Lock
Alarm Module: Testing and Inspection Content Theft Deterrent (CTD) Does Not Disarm with Key
Lock
Content Theft Deterrent (CTD) Does Not Disarm with Key Lock
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The content theft deterrent (CTD) system is a software based system in which the body control
module (BCM) actively monitors certain inputs to determine if unauthorized vehicle access is being
attempted. The driver door lock cylinder switch is used as an input to disarm the CTD system. The
BCM monitors the door lock key switch unlock signal circuit to determine if the driver door cylinder
is being rotated, indicating a vehicle key is being used to unlock the vehicle and the CTD system
should be disarmed. The door key cylinder switch, located in the driver door latch assembly,
provides a switched ground for the signal circuit.
Circuit/System Verification
Ignition ON, verify the scan tool Door Key Cyl. Unlock Switch parameter cycles between Inactive
and Active while turning the driver door lock cylinder with the vehicle key.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the driver door latch assembly. 2. Ignition
OFF, test for less than 10 ohms of resistance between the ground circuit terminal 8 and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
3. Ignition ON, verify the scan tool Door Key Cyl. Unlock Switch parameter is Inactive.
‹› If not the specified value, test the signal circuit terminal 9 for a short to ground. If the circuit tests
normal, replace the BCM.
4. Install a 3-A fused jumper wire between the signal circuit terminal 9 and ground. Verify the scan
tool Door Key Cyl. Unlock Switch parameter is
Active.
‹› If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If
the circuit tests normal, replace the BCM.
5. If all circuits test normal, test or replace the door latch assembly.
Component Testing
1. Ignition OFF, disconnect the harness connector at the driver door latch assembly. 2. Test for
infinite resistance between the signal terminal 9 and the ground terminal 8 with the switch in the
open position.
‹› If not the specified value, replace the door latch assembly.
3. Test for less than 2.0 ohms of resistance between the signal terminal 9 and the ground terminal
8 with the switch in the closed position.
‹› If greater than the specified range, replace the door latch assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent (CTD) Does Not
Disarm with Key Lock > Page 13
4. Test for infinite resistance between each terminal and the door latch assembly housing/case.
‹› If not the specified value, replace the door latch assembly.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Front Side Door Lock Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent (CTD) Does Not
Disarm with Key Lock > Page 14
Alarm Module: Testing and Inspection Content Theft Deterrent Malfunction
Content Theft Deterrent Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The content theft deterrent (CTD) system is a software based system in which the body control
module (BCM) actively monitors certain inputs to determine if unauthorized vehicle access is being
attempted. Based on inputs such as the door ajar switches, the rear compartment ajar switch, and
the hood ajar switch, the BCM determines whether a CTD alarm is warranted. If unauthorized
access is being detected, the BCM will pulse the vehicle horn and flash the turn signals as a means
of theft deterrence.
Circuit/System Verification
1. Individually open and close each vehicle door while observing the door ajar indicator/message.
The indicator/message should accurately transition
between the door ajar and door closed state when each door is opened and closed.
‹› If the door ajar indicator/message does not properly transition when each door is opened and
closed, refer to Door Ajar Indicator Malfunction.
See: Body and Frame/Locks/Testing and Inspection/Symptom Related Diagnostic
Procedures/Door Ajar Indicator Malfunction
2. Open and close the trunk while observing the trunk ajar indicator/message. The
indicator/message should accurately transition between the trunk
ajar and trunk closed state when the trunk is opened and closed.
‹› If the trunk ajar indicator/message does not properly transition when the trunk is opened and
closed, refer to Trunk Ajar Indicator Malfunction.
3. Insert the vehicle key into the driver door key cylinder and rotate the cylinder between the lock
and unlock positions. Verify the scan tool Door
Key Cyl. Unlock Switch parameter cycles between Idle/Inactive and Unlock/Active.
‹› If the scan tool parameter does not cycle between the specified parameters, refer to Content
Theft Deterrent (CTD) Does Not Disarm with Key
Lock. See: Content Theft Deterrent (CTD) Does Not Disarm with Key Lock
4. Completely lower the driver door window and close all vehicle doors. 5. Ignition OFF, arm the
CTD system using the keyless entry system by pressing the transmitter LOCK button twice. Verify
the scan tool CTD Status
parameter displays Armed.
‹› If the parameter does not equal the specified value, refer to Keyless Entry System Inoperative.
See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related
Diagnostic Procedures/Keyless Entry System Inoperative
6. Without disarming the system, reach in through the open driver window, unlock and open the
driver door. Verify the scan tool CTD Status
parameter displays Alarm Active.
‹› If the parameter does not equal the specified value, replace the BCM.
7. With the door open, verify the vehicle horn is pulsing and the exterior lamps are flashing.
‹› If the horn is not pulsing, refer to Horns Malfunction. See: Lighting and Horns/Horn/Testing and
Inspection/Symptom Related Diagnostic
Procedures/Horns Malfunction
‹› If the exterior lights are not flashing, refer to Turn Signal Lamps and/or Indicators Malfunction.
See: Lighting and Horns/Testing and
Inspection/Symptom Related Diagnostic Procedures/Turn Signal Lamps and/or Indicators
Malfunction
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent (CTD) Does Not
Disarm with Key Lock > Page 15
Alarm Module: Testing and Inspection Security Indicator Malfunction
Security Indicator Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provide an overview of each diagnostic category.
Circuit/System Description
The security indicator acts as a status indicator for the content theft deterrent (CTD) system when
the ignition is OFF and as a fault indicator for the immobilizer system when the ignition is ON.
When either the body control module (BCM) or theft deterrent module (TDM) requires the security
indicator to be illuminated, a serial data message is sent to the instrument panel cluster (IPC),
which will illuminate the indicator.
Circuit/System Verification
Ignition ON, verify the security indicator illuminates when performing the scan tool IPC Display
Test.
If the security indicator does not illuminate, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Page 16
Alarm Module: Service and Repair
Theft Deterrent Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations
Central Control Module: Locations
Luggage Compartment/Rear of Vehicle Component Views
Left Side of Rear Compartment
1 - Vehicle Communication Interface Module (VCIM) (UE1) 2 - Vehicle Communication Interface
Module (VCIM) Battery (UE1) 3 - Data Link Resistor (UE1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 20
Central Control Module: Diagrams
Component Connector End Views - Continued
Vehicle Communication Interface Module (VCIM) X1
Vehicle Communication Interface Module (VCIM) X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 21
Vehicle Communication Interface Module (VCIM) Battery
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 22
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 31
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 32
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 33
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 39
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 40
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 41
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 46
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 52
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Service and Repair > Communication Interface Module
Replacement
Communications Control Module: Service and Repair Communication Interface Module
Replacement
Communication Interface Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Service and Repair > Communication Interface Module
Replacement > Page 55
Communications Control Module: Service and Repair Communication Interface Module Battery
Replacement
Communication Interface Module Battery Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Service and Repair > Communication Interface Module
Replacement > Page 56
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 65
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 70
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
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> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 75
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 76
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 82
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position
Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call >
Page 99
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands
Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page
104
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page
105
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 110
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 111
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 112
Method 1
Method 2
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 113
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 131
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 132
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 133
Method 1
Method 2
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 134
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Keyless Entry Module > Component Information > Service and Repair > Remote Control Door Lock Receiver Antenna
Replacement
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Antenna
Replacement
Remote Control Door Lock Receiver Antenna Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Keyless Entry Module > Component Information > Service and Repair > Remote Control Door Lock Receiver Antenna
Replacement > Page 139
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement
Remote Control Door Lock Receiver Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 148
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 149
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 150
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 156
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 157
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 158
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay >
Component Information > Locations
Door Lock Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Remote Control Door Lock Receiver Antenna Replacement
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Antenna
Replacement
Remote Control Door Lock Receiver Antenna Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair > Remote Control Door Lock Receiver Antenna Replacement > Page 167
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement
Remote Control Door Lock Receiver Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: Customer Interest Electrical - No Crank/Start Discharged or Low
Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 176
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control
Module: > 10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/Start Discharged
or Low Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control
Module: > 10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 182
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 183
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Driver Seat Components
1 - Seat Recline Motor - Driver (AH5) 2 - Heated Seat Element - Driver - Back (KA1) 3 - Seat
Adjuster Switch - Driver 4 - Heated Seat Control Module (KA1) 5 - Horizontal Motor (Part of the
Seat Adjuster Motor Assembly - Driver) 6 - Front Vertical Motor (Part of the Seat Adjuster Motor
Assembly - Driver) 7 - Rear Vertical Motor (Part of the Seat Adjuster Motor Assembly - Driver) 8 Heated Seat Element - Driver - Seat (KA1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 184
Seat Heater Control Module: Diagrams
Component Connector End Views
Heated Seat Control Module X1
Heated Seat Control Module X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 185
Heated Seat Control Module X3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 186
Heated Seat Control Module X4
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 187
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay >
Component Information > Locations
Trunk / Liftgate Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-05-25-001 > Jun >
09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: Customer Interest ABS/TCS - Stabiltrak Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Stabiltrak
Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
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Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 210
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 211
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 212
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 213
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 219
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 220
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 221
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 222
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Powertrain Component Views
Electronic Brake Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Powertrain Component Views > Page 225
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 226
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM) (without JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 227
Electronic Brake Control Module (EBCM) (JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 228
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 229
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Recalls: > 08266 > Aug > 08 > Campaign - A/C Control Module Reprogramming
Technical Service Bulletin # 08266 Date: 080812
Campaign - A/C Control Module Reprogramming
# 08266: Customer Satisfaction - Reduced Heating and Cooling-Reprogram Module - (Aug 12,
2008)
Subject: 08266 -- Reduced Heating and Cooling - Reprogram - Module - (Aug 12, 2008)
Models: 2008 Chevrolet Impala
With Dual Zone Manual Climate Control (RPO CJ3)
THIS PROGRAM IS IN EFFECT UNTIL AUGUST 31, 2009.
Condition
Certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual climate
control (RPO CJ3) may have software that does not allow the heating and air conditioning system
to deliver maximum cold or maximum hot output. If this occurs, the vehicle may not warm or cool
as intended.
Correction
Dealers are to reprogram the HVAC control head module.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual
climate control (RPO CJ3) and built within the VIN breakpoints shown above.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
- US dealers - GM DealerWorld Recall Information
- Canadian dealers - GMinfoNet Recall Reports
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
No parts are required for the program.
Service Procedure
Do not attempt to order the calibration number from GMSPO. The calibration numbers required for
this service procedure are programmed into control modules via a Multiple Diagnostic Interface
(MDI) or Tech 2(R) scan tool and TIS2WEB with the calibration update. Use TIS2WEB on or after
07/30/08 to obtain the calibration. If you cannot access the calibration, call the Techline Customer
Support Center and it will be provided.
Service Programming System (SPS)
For step-by-step programming instructions, please refer to SI and the Techline Information System
(TIS) terminal.
Review the information below to ensure proper programming protocol.
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Information > Technical Service Bulletins > Recalls: > 08266 > Aug > 08 > Campaign - A/C Control Module Reprogramming
> Page 242
Important:
^ DO NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporation service bulletin. Programming a control module at any
other time will not permanently correct a customer's concern.
^ It is essential that the Multiple Diagnostic Interface (MDI) or Tech 2(R) and the TIS terminal are
equipped with the latest software before performing (SPS).
^ Due to the time requirements of programming a controller, it is recommended that an external
power source be used to maintain system voltage. Stable battery voltage is critical during
programming. Any fluctuation, spiking, over voltage or loss of voltage will interrupt programming.
To ensure trouble-free programming, GM recommends using one of the following external power
sources:
- A Midtronic PCS charger.
- A fully charged 12V jumper or booster pack disconnected from the AC voltage supply.
- Some modules will require additional programming/setup events performed before or after
programming.
- Some vehicles may require the use of a CANDi module for programming.
- Review the appropriate service information for these procedures.
- DTCs may set during programming. Clear DTCs after programming is complete.
- Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to
NO.
Ensure the following conditions are met before programming a control module:
- Flex Fuel (E85) Vehicles
- The fuel composition learn function is inactive. Programming with the fuel composition learn
active will result in fuel trim DTCs.
- If necessary, drive the vehicle until the scan tool indicates that the fuel composition learn is
inactive.
Vehicle System Voltage
- There is not a charging system concern. All charging system concerns must be repaired before
programming a control module.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged
before programming the control module.
- Turn OFF or disable any system that may put a load on the vehicles battery, such as the following
components:
- Twilight sentinel
- Interior lights
- Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL
system
- Heating, ventilation and air conditioning (HVAC) systems
- Engine cooling fans, radio, etc.
The ignition switch must be in the proper position. SPS prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of the ignition switch during the programming
procedure, unless instructed to do so
Make certain all tool connections are secure, including the following components and circuits:
- The RS-232 communication cable port.
- The connection at the data link connector (DLC)
- The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
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Information > Technical Service Bulletins > Recalls: > 08266 > Aug > 08 > Campaign - A/C Control Module Reprogramming
> Page 243
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date. Attempt to reprogram the control module. If the control module cannot be programmed,
replace the control module.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Only use approved Midtronics PCS charger, a fully charged 12V
jumper, or booster pack disconnected from the AC voltage supply to maintain proper battery
voltage during programming.
2. Reprogram the HVAC control module. Refer to SI and Service Programming System (SPS)
documentation for programming instructions, if required.
2.1 Connect the MDI or Tech2(R) to the vehicle.
Important:
Select J2534 MDI or Tech 2(R) Legacy Pass-Thru and Reprogram ECU from the Select Diagnostic
Tool and Programming Process screen. The J2534 MDI will reprogram the module in less time
than the Tech 2(R) scan tool.
2.2. Select HVAC Control Module from the Supported Controllers screen.
2.3. Follow the on-screen instructions. Select HVAC Control Module with Manual Dual Zone (RPO
CJ3).
2.4. Select Latest New Calibrations to Enable OAT for use with up level instrument panel (RPO
UH8).
3. Using the MDI or Tech 2(R), clear all DTCs if required.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
Submit a Product Claim with the information shown above.
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Customer Notification
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Dealer Program Responsibility
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
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Information > Technical Service Bulletins > Recalls: > 08266 > Aug > 08 > Campaign - A/C Control Module Reprogramming
> Page 244
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of
mileage, age of vehicle, or ownership, through August 31, 2009.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Program follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is
inventory, or is in your dealership for service through August 31, 2009, you must take the steps
necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Customer Interest: > 07-01-39-008A > Apr > 09 > A/C - System Unable to
Maintain Desired Temperature
Control Module HVAC: Customer Interest A/C - System Unable to Maintain Desired Temperature
TECHNICAL
Bulletin No.: 07-01-39-008A
Date: April 17, 2009
Subject: HVAC System Unable to Maintain Desired Temperature Inside Vehicle (Update HVAC
Control Module Software)
Models: 2007 Chevrolet Monte Carlo 2007-2008 Chevrolet Impala
with Manual Control HVAC System (RPO C67) or Manual Control HVAC System (RPO CJ3)
Supercede: This bulletin is being revised to update RPO Information. Please discard Corporate
Bulletin Number 07-01-39-008 (Section 01 - HVAC).
Condition
Some customers may comment that the temperature selected on the HVAC control head is not
being maintained inside the vehicle.
Cause
This condition may be caused by the temperature doors losing their positions.
Correction
Important
There are two calibrations part numbers that are valid for HVAC. Read the descriptions and RPO
Codes to determine the correct calibration for your vehicle.
A new calibration has been released that periodically relearns the temperature door positions and
prevents the doors from becoming lost. Technicians are to reprogram the HVAC control module
with the updated software calibration using SPS. This new service calibration is available on
TIS2WEB.
It is recommended that the HVAC actuators be recalibrated after the HVAC control module
software is updated. Refer to Actuator Recalibration in the HVAC Control Module Programing and
Setup section of SI for more information. When completed, the command state for the actuators will
change from "None" to "On".
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Customer Interest: > 07-01-39-008A > Apr > 09 > A/C - System Unable to
Maintain Desired Temperature > Page 250
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 07-01-39-008A >
Apr > 09 > A/C - System Unable to Maintain Desired Temperature
Control Module HVAC: All Technical Service Bulletins A/C - System Unable to Maintain Desired
Temperature
TECHNICAL
Bulletin No.: 07-01-39-008A
Date: April 17, 2009
Subject: HVAC System Unable to Maintain Desired Temperature Inside Vehicle (Update HVAC
Control Module Software)
Models: 2007 Chevrolet Monte Carlo 2007-2008 Chevrolet Impala
with Manual Control HVAC System (RPO C67) or Manual Control HVAC System (RPO CJ3)
Supercede: This bulletin is being revised to update RPO Information. Please discard Corporate
Bulletin Number 07-01-39-008 (Section 01 - HVAC).
Condition
Some customers may comment that the temperature selected on the HVAC control head is not
being maintained inside the vehicle.
Cause
This condition may be caused by the temperature doors losing their positions.
Correction
Important
There are two calibrations part numbers that are valid for HVAC. Read the descriptions and RPO
Codes to determine the correct calibration for your vehicle.
A new calibration has been released that periodically relearns the temperature door positions and
prevents the doors from becoming lost. Technicians are to reprogram the HVAC control module
with the updated software calibration using SPS. This new service calibration is available on
TIS2WEB.
It is recommended that the HVAC actuators be recalibrated after the HVAC control module
software is updated. Refer to Actuator Recalibration in the HVAC Control Module Programing and
Setup section of SI for more information. When completed, the command state for the actuators will
change from "None" to "On".
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 07-01-39-008A >
Apr > 09 > A/C - System Unable to Maintain Desired Temperature > Page 256
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming
Technical Service Bulletin # 08266 Date: 080812
Campaign - A/C Control Module Reprogramming
# 08266: Customer Satisfaction - Reduced Heating and Cooling-Reprogram Module - (Aug 12,
2008)
Subject: 08266 -- Reduced Heating and Cooling - Reprogram - Module - (Aug 12, 2008)
Models: 2008 Chevrolet Impala
With Dual Zone Manual Climate Control (RPO CJ3)
THIS PROGRAM IS IN EFFECT UNTIL AUGUST 31, 2009.
Condition
Certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual climate
control (RPO CJ3) may have software that does not allow the heating and air conditioning system
to deliver maximum cold or maximum hot output. If this occurs, the vehicle may not warm or cool
as intended.
Correction
Dealers are to reprogram the HVAC control head module.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual
climate control (RPO CJ3) and built within the VIN breakpoints shown above.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
- US dealers - GM DealerWorld Recall Information
- Canadian dealers - GMinfoNet Recall Reports
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
No parts are required for the program.
Service Procedure
Do not attempt to order the calibration number from GMSPO. The calibration numbers required for
this service procedure are programmed into control modules via a Multiple Diagnostic Interface
(MDI) or Tech 2(R) scan tool and TIS2WEB with the calibration update. Use TIS2WEB on or after
07/30/08 to obtain the calibration. If you cannot access the calibration, call the Techline Customer
Support Center and it will be provided.
Service Programming System (SPS)
For step-by-step programming instructions, please refer to SI and the Techline Information System
(TIS) terminal.
Review the information below to ensure proper programming protocol.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 261
Important:
^ DO NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporation service bulletin. Programming a control module at any
other time will not permanently correct a customer's concern.
^ It is essential that the Multiple Diagnostic Interface (MDI) or Tech 2(R) and the TIS terminal are
equipped with the latest software before performing (SPS).
^ Due to the time requirements of programming a controller, it is recommended that an external
power source be used to maintain system voltage. Stable battery voltage is critical during
programming. Any fluctuation, spiking, over voltage or loss of voltage will interrupt programming.
To ensure trouble-free programming, GM recommends using one of the following external power
sources:
- A Midtronic PCS charger.
- A fully charged 12V jumper or booster pack disconnected from the AC voltage supply.
- Some modules will require additional programming/setup events performed before or after
programming.
- Some vehicles may require the use of a CANDi module for programming.
- Review the appropriate service information for these procedures.
- DTCs may set during programming. Clear DTCs after programming is complete.
- Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to
NO.
Ensure the following conditions are met before programming a control module:
- Flex Fuel (E85) Vehicles
- The fuel composition learn function is inactive. Programming with the fuel composition learn
active will result in fuel trim DTCs.
- If necessary, drive the vehicle until the scan tool indicates that the fuel composition learn is
inactive.
Vehicle System Voltage
- There is not a charging system concern. All charging system concerns must be repaired before
programming a control module.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged
before programming the control module.
- Turn OFF or disable any system that may put a load on the vehicles battery, such as the following
components:
- Twilight sentinel
- Interior lights
- Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL
system
- Heating, ventilation and air conditioning (HVAC) systems
- Engine cooling fans, radio, etc.
The ignition switch must be in the proper position. SPS prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of the ignition switch during the programming
procedure, unless instructed to do so
Make certain all tool connections are secure, including the following components and circuits:
- The RS-232 communication cable port.
- The connection at the data link connector (DLC)
- The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 262
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date. Attempt to reprogram the control module. If the control module cannot be programmed,
replace the control module.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Only use approved Midtronics PCS charger, a fully charged 12V
jumper, or booster pack disconnected from the AC voltage supply to maintain proper battery
voltage during programming.
2. Reprogram the HVAC control module. Refer to SI and Service Programming System (SPS)
documentation for programming instructions, if required.
2.1 Connect the MDI or Tech2(R) to the vehicle.
Important:
Select J2534 MDI or Tech 2(R) Legacy Pass-Thru and Reprogram ECU from the Select Diagnostic
Tool and Programming Process screen. The J2534 MDI will reprogram the module in less time
than the Tech 2(R) scan tool.
2.2. Select HVAC Control Module from the Supported Controllers screen.
2.3. Follow the on-screen instructions. Select HVAC Control Module with Manual Dual Zone (RPO
CJ3).
2.4. Select Latest New Calibrations to Enable OAT for use with up level instrument panel (RPO
UH8).
3. Using the MDI or Tech 2(R), clear all DTCs if required.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
Submit a Product Claim with the information shown above.
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Customer Notification
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Dealer Program Responsibility
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 263
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of
mileage, age of vehicle, or ownership, through August 31, 2009.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Program follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is
inventory, or is in your dealership for service through August 31, 2009, you must take the steps
necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 07-01-39-008A > Apr >
09 > A/C - System Unable to Maintain Desired Temperature
Control Module HVAC: All Technical Service Bulletins A/C - System Unable to Maintain Desired
Temperature
TECHNICAL
Bulletin No.: 07-01-39-008A
Date: April 17, 2009
Subject: HVAC System Unable to Maintain Desired Temperature Inside Vehicle (Update HVAC
Control Module Software)
Models: 2007 Chevrolet Monte Carlo 2007-2008 Chevrolet Impala
with Manual Control HVAC System (RPO C67) or Manual Control HVAC System (RPO CJ3)
Supercede: This bulletin is being revised to update RPO Information. Please discard Corporate
Bulletin Number 07-01-39-008 (Section 01 - HVAC).
Condition
Some customers may comment that the temperature selected on the HVAC control head is not
being maintained inside the vehicle.
Cause
This condition may be caused by the temperature doors losing their positions.
Correction
Important
There are two calibrations part numbers that are valid for HVAC. Read the descriptions and RPO
Codes to determine the correct calibration for your vehicle.
A new calibration has been released that periodically relearns the temperature door positions and
prevents the doors from becoming lost. Technicians are to reprogram the HVAC control module
with the updated software calibration using SPS. This new service calibration is available on
TIS2WEB.
It is recommended that the HVAC actuators be recalibrated after the HVAC control module
software is updated. Refer to Actuator Recalibration in the HVAC Control Module Programing and
Setup section of SI for more information. When completed, the command state for the actuators will
change from "None" to "On".
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 07-01-39-008A > Apr >
09 > A/C - System Unable to Maintain Desired Temperature > Page 269
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming
Technical Service Bulletin # 08266 Date: 080812
Campaign - A/C Control Module Reprogramming
# 08266: Customer Satisfaction - Reduced Heating and Cooling-Reprogram Module - (Aug 12,
2008)
Subject: 08266 -- Reduced Heating and Cooling - Reprogram - Module - (Aug 12, 2008)
Models: 2008 Chevrolet Impala
With Dual Zone Manual Climate Control (RPO CJ3)
THIS PROGRAM IS IN EFFECT UNTIL AUGUST 31, 2009.
Condition
Certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual climate
control (RPO CJ3) may have software that does not allow the heating and air conditioning system
to deliver maximum cold or maximum hot output. If this occurs, the vehicle may not warm or cool
as intended.
Correction
Dealers are to reprogram the HVAC control head module.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Impala vehicles equipped with dual zone manual
climate control (RPO CJ3) and built within the VIN breakpoints shown above.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
- US dealers - GM DealerWorld Recall Information
- Canadian dealers - GMinfoNet Recall Reports
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
No parts are required for the program.
Service Procedure
Do not attempt to order the calibration number from GMSPO. The calibration numbers required for
this service procedure are programmed into control modules via a Multiple Diagnostic Interface
(MDI) or Tech 2(R) scan tool and TIS2WEB with the calibration update. Use TIS2WEB on or after
07/30/08 to obtain the calibration. If you cannot access the calibration, call the Techline Customer
Support Center and it will be provided.
Service Programming System (SPS)
For step-by-step programming instructions, please refer to SI and the Techline Information System
(TIS) terminal.
Review the information below to ensure proper programming protocol.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 275
Important:
^ DO NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporation service bulletin. Programming a control module at any
other time will not permanently correct a customer's concern.
^ It is essential that the Multiple Diagnostic Interface (MDI) or Tech 2(R) and the TIS terminal are
equipped with the latest software before performing (SPS).
^ Due to the time requirements of programming a controller, it is recommended that an external
power source be used to maintain system voltage. Stable battery voltage is critical during
programming. Any fluctuation, spiking, over voltage or loss of voltage will interrupt programming.
To ensure trouble-free programming, GM recommends using one of the following external power
sources:
- A Midtronic PCS charger.
- A fully charged 12V jumper or booster pack disconnected from the AC voltage supply.
- Some modules will require additional programming/setup events performed before or after
programming.
- Some vehicles may require the use of a CANDi module for programming.
- Review the appropriate service information for these procedures.
- DTCs may set during programming. Clear DTCs after programming is complete.
- Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to
NO.
Ensure the following conditions are met before programming a control module:
- Flex Fuel (E85) Vehicles
- The fuel composition learn function is inactive. Programming with the fuel composition learn
active will result in fuel trim DTCs.
- If necessary, drive the vehicle until the scan tool indicates that the fuel composition learn is
inactive.
Vehicle System Voltage
- There is not a charging system concern. All charging system concerns must be repaired before
programming a control module.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged
before programming the control module.
- Turn OFF or disable any system that may put a load on the vehicles battery, such as the following
components:
- Twilight sentinel
- Interior lights
- Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL
system
- Heating, ventilation and air conditioning (HVAC) systems
- Engine cooling fans, radio, etc.
The ignition switch must be in the proper position. SPS prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of the ignition switch during the programming
procedure, unless instructed to do so
Make certain all tool connections are secure, including the following components and circuits:
- The RS-232 communication cable port.
- The connection at the data link connector (DLC)
- The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 276
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date. Attempt to reprogram the control module. If the control module cannot be programmed,
replace the control module.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Only use approved Midtronics PCS charger, a fully charged 12V
jumper, or booster pack disconnected from the AC voltage supply to maintain proper battery
voltage during programming.
2. Reprogram the HVAC control module. Refer to SI and Service Programming System (SPS)
documentation for programming instructions, if required.
2.1 Connect the MDI or Tech2(R) to the vehicle.
Important:
Select J2534 MDI or Tech 2(R) Legacy Pass-Thru and Reprogram ECU from the Select Diagnostic
Tool and Programming Process screen. The J2534 MDI will reprogram the module in less time
than the Tech 2(R) scan tool.
2.2. Select HVAC Control Module from the Supported Controllers screen.
2.3. Follow the on-screen instructions. Select HVAC Control Module with Manual Dual Zone (RPO
CJ3).
2.4. Select Latest New Calibrations to Enable OAT for use with up level instrument panel (RPO
UH8).
3. Using the MDI or Tech 2(R), clear all DTCs if required.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
Submit a Product Claim with the information shown above.
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Customer Notification
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Dealer Program Responsibility
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 08266 > Aug > 08 >
Campaign - A/C Control Module Reprogramming > Page 277
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of
mileage, age of vehicle, or ownership, through August 31, 2009.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in
contacting customers. Program follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is
inventory, or is in your dealership for service through August 31, 2009, you must take the steps
necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Page 278
Control Module HVAC: Locations
Instrument Panel/Center Console Component Views
Interior HVAC Components
1 - HVAC Module 2 - Mode Actuator 3 - Air Temperature Actuator (C67), Air Temperature Actuator
- Right (CJ3) 4 - Recirculation Actuator 5 - Blower Motor 6 - Blower Motor Control Module 7 - Air
Temperature Actuator - Left (CJ3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Page 279
Control Module HVAC: Diagrams
Component Connector End Views
Blower Motor Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Page 280
Control Module HVAC: Service and Repair
Blower Motor Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
07-09-41-008B > Feb > 08 > Restraints - Air Bag Lamp ON/DTC B1019
Instrument Panel Control Module: Customer Interest Restraints - Air Bag Lamp ON/DTC B1019
Bulletin No.: 07-09-41-008B
Date: February 07, 2008
TECHNICAL
Subject: Air Bag Readiness Light On, DTC B1019 Set in Sensing and Diagnostic Module (SDM)
(Reprogram Instrument Panel Cluster (IPC))
Models: 2006-2008 Buick Lucerne
Built Prior to January 8, 2008
2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Built Prior to November 19, 2007 (VIN Breakpoint 89276078)
Supercede:
This bulletin is being revised to add the 2008 Buick Lucerne and to provide production
implementation dates. Please discard Corporate Bulletin Number 07-09-41-008A (Section 09 Restraints).
Condition
Some customers may comment on the air bag readiness light being illuminated.
A scan tool may reveal DTC B1019 with a symptom code of 3A set as history in the SDM.
If the code is set as current, use the appropriate SI instructions for this DTC to troubleshoot this
concern.
Cause
The instrument panel cluster (IPC) has failed to detect the passenger airbag ON/OFF indicator due
to a software timing concern and has transmitted this information to the SDM. The IPC can fail to
detect this ON/OFF indicator if there is an unbuckled passenger and the vehicle is running because
the IPC is checking the status of the indicator at the incorrect timing interval. This DTC can also set
more frequently in low voltage operation.
Correction
A revised IPC calibration has been developed to address this issue. Reprogram the IPC with
updated calibration files using the TIS2WEB Service Programming System (SPS) application. As
always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
07-09-41-008B > Feb > 08 > Restraints - Air Bag Lamp ON/DTC B1019 > Page 290
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 07-09-41-008B > Feb > 08 > Restraints - Air Bag Lamp ON/DTC B1019
Instrument Panel Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp
ON/DTC B1019
Bulletin No.: 07-09-41-008B
Date: February 07, 2008
TECHNICAL
Subject: Air Bag Readiness Light On, DTC B1019 Set in Sensing and Diagnostic Module (SDM)
(Reprogram Instrument Panel Cluster (IPC))
Models: 2006-2008 Buick Lucerne
Built Prior to January 8, 2008
2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Built Prior to November 19, 2007 (VIN Breakpoint 89276078)
Supercede:
This bulletin is being revised to add the 2008 Buick Lucerne and to provide production
implementation dates. Please discard Corporate Bulletin Number 07-09-41-008A (Section 09 Restraints).
Condition
Some customers may comment on the air bag readiness light being illuminated.
A scan tool may reveal DTC B1019 with a symptom code of 3A set as history in the SDM.
If the code is set as current, use the appropriate SI instructions for this DTC to troubleshoot this
concern.
Cause
The instrument panel cluster (IPC) has failed to detect the passenger airbag ON/OFF indicator due
to a software timing concern and has transmitted this information to the SDM. The IPC can fail to
detect this ON/OFF indicator if there is an unbuckled passenger and the vehicle is running because
the IPC is checking the status of the indicator at the incorrect timing interval. This DTC can also set
more frequently in low voltage operation.
Correction
A revised IPC calibration has been developed to address this issue. Reprogram the IPC with
updated calibration files using the TIS2WEB Service Programming System (SPS) application. As
always make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
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Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 07-09-41-008B > Feb > 08 > Restraints - Air Bag Lamp ON/DTC B1019 > Page 296
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations
Daytime Running Lamp Relay: Locations
DAYTIME RUNNING LAMPS (DRL) RELAY
The Daytime Running Lamps PCB relay is located in the Underhood Fuse Block (1). The
Underhood Fuse Block (1) is located on the right side of the engine compartment, mounted to the
strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay
> Component Information > Locations
Fog/Driving Lamp Relay: Locations
FOG LAMPS RELAY
The Fog Lamps PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
High Beam Relay: Locations
HIGH BEAM RELAY
The High Beam PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay >
Component Information > Locations
Horn Relay: Locations
HORN RELAY
The Horn PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block (1) is
located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Low Beam Relay: Locations
LOW BEAM RELAY
The Low Beam PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
PARK LAMPS RELAY
The Park Lamps PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse
Block (1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Accessory
Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
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324
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
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325
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
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> Body Controls - Unable To Reprogram Body Control Module > Page 332
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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> Body Controls - Unable To Reprogram Body Control Module > Page 333
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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> Body Controls - Unable To Reprogram Body Control Module > Page 334
Disclaimer
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 335
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Near the Steering Column
1 - Instrument Panel Carrier 2 - Inflatable Restraint Steering Wheel Module 3 - Steering Column 4 Body Control Module (BCM)
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 336
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 337
Body Control Module (BCM) X2
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 338
Body Control Module (BCM) X3
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 339
Body Control Module (BCM) X4
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 340
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 341
Body Control Module (BCM) X5
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 342
Body Control Module (BCM) X6
Body Control Module (BCM) X7
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> Page 343
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 344
Body Control Module: Service and Repair
Body Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 349
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 350
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 351
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 354
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
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3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 357
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Front of
Vehicle/Engine Compartment Component Views
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Engine Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Engine Control Module: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Engine Control Module: Connector Views
Component Connector End Views
Engine Control Module (ECM) X1 (LS4)
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Engine Control Module (ECM) X2 (LS4)
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Engine Control Module (ECM) X2 (LS4) (Pin 1 To 33)
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Engine Control Module (ECM) X2 (LS4) (Pin 34 To 73)
Engine Control Module (ECM) X3 (LS4)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for ECM replacement, inspect the ECM first to see if the replacement is
the correct part. If the ECM is faulty, remove the ECM and install the new service ECM.
The new service ECM will not be programmed. You must program the new ECM. DTC P0602
indicates the EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch
the connector pins or the soldered components on the circuit board.
Notice: Always turn the ignition off when installing or removing the ECM connectors in order to
prevent damage to the components.
Removal Procedure
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life, if required. 2. Disconnect the negative battery cable. 3. Remove the left front inner fender
brace. 4. Remove the air cleaner assembly. 5. Disconnect the ECM electrical connectors (2).
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6. Remove the ECM from the air cleaner lower housing.
Installation Procedure
1. Install the ECM to the air cleaner lower housing.
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2. Connect the ECM electrical connectors (2). 3. Install the air cleaner assembly. 4. Install the left
front inner fender brace. 5. Connect the negative battery cable. 6. Program the new ECM. See:
Testing and Inspection/Programming and Relearning
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Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
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^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
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Air Injection Pump Relay: Diagrams
Component Connector End Views - Continued
Secondary Air Injection (AIR) Pump Relay (NU3)
Secondary Air Injection (AIR) Solenoid Relay (NU3)
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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and Instructions
Fuel Pump Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 641
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and Instructions > Page 642
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
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Page 646
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 647
^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 657
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 658
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC
Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 664
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 665
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 666
Air Bag Control Module: Locations
Passenger Compartment/Roof Component Views
Under the Passenger Seat
1 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 2 - Front Passenger Floor Panel
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 667
Air Bag Control Module: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Sensing and Diagnostic Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 668
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 669
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tire Monitor System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views > Page 690
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 691
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 692
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 693
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay >
Component Information > Locations
Rear Defogger Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations
Windshield Washer Relay: Locations
WINDSHIELD WASHER RELAY
The Windshield Washer PCB relay is located in the Underhood Fuse Block (1). The Underhood
Fuse Block (1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Wiper High Relay
Wiper Relay: Locations Wiper High Relay
WIPER HIGH RELAY
The Wiper High PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Wiper High Relay > Page 706
Wiper Relay: Locations Wiper Relay
WIPER RELAY
The Wiper PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block (1) is
located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Locations
Hood Sensor/Switch (For Alarm): Locations
Front of Vehicle/Engine Compartment Component Views
Under the Hood Latch Trim Panel
1 - Ambient Air Temperature Sensor 2 - Hood Ajar Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 712
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views - Continued
Hood Ajar Switch (AP3, AP8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Locations > Page 716
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Service and Repair > Procedures
Pedal Positioning Sensor: Procedures
Brake Pedal Position Sensor Calibration
Calibration Criteria
The brake pedal position sensor (BPPS) receives a low reference signal and a 10-volt reference
signal from the body control module (BCM). Whenever the brake pedal is applied, the brake pedal
position sensor applies a variable voltage signal to the BCM through the stop lamp switch signal
circuit. Brake pedal position sensor calibration must be performed after the brake pedal position
sensor or BCM have been serviced. The calibration procedure will set brake pedal position sensor
home value. This value is used by the BCM to determine the action of the driver applying the brake
system and to provide this information to the vehicle subsystems via the class 2 communication
bus.
Calibration Procedure
Important: If the master brake cylinder has been replaced, verify that the correct pushrod is
installed before attempting to calibrate the brake pedal position sensor.
1. Turn ON the ignition, with the engine OFF. 2. Install a scan tool, select the proper vehicle and
options. 3. Navigate to the BCM menu. 4. Select Module Setup menu item. 5. Select the BPPS
sensor calibration procedure and follow the directions displayed on the screen.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Service and Repair > Procedures > Page 719
Pedal Positioning Sensor: Removal and Replacement
Brake Pedal Position Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering
Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Steering Mounted Controls Assembly > Component Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor
> Hood Sensor/Switch (For Alarm) > Component Information > Locations
Hood Sensor/Switch (For Alarm): Locations
Front of Vehicle/Engine Compartment Component Views
Under the Hood Latch Trim Panel
1 - Ambient Air Temperature Sensor 2 - Hood Ajar Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor
> Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 732
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views - Continued
Hood Ajar Switch (AP3, AP8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Locations > Page 736
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Service and Repair > Procedures
Pedal Positioning Sensor: Procedures
Brake Pedal Position Sensor Calibration
Calibration Criteria
The brake pedal position sensor (BPPS) receives a low reference signal and a 10-volt reference
signal from the body control module (BCM). Whenever the brake pedal is applied, the brake pedal
position sensor applies a variable voltage signal to the BCM through the stop lamp switch signal
circuit. Brake pedal position sensor calibration must be performed after the brake pedal position
sensor or BCM have been serviced. The calibration procedure will set brake pedal position sensor
home value. This value is used by the BCM to determine the action of the driver applying the brake
system and to provide this information to the vehicle subsystems via the class 2 communication
bus.
Calibration Procedure
Important: If the master brake cylinder has been replaced, verify that the correct pushrod is
installed before attempting to calibrate the brake pedal position sensor.
1. Turn ON the ignition, with the engine OFF. 2. Install a scan tool, select the proper vehicle and
options. 3. Navigate to the BCM menu. 4. Select Module Setup menu item. 5. Select the BPPS
sensor calibration procedure and follow the directions displayed on the screen.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Service and Repair > Procedures > Page 739
Pedal Positioning Sensor: Removal and Replacement
Brake Pedal Position Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations
Power Door Lock Switch: Locations
Door Component Views
Driver Door
1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Door Lock Switch - Driver 4 - Window
Switch - Driver 5 - Outside Rearview Mirror Switch 6 - Window Motor - Driver 7 - Inflatable
Restraint Side Impact Sensor (SIS) Left (AY1) 8 - Door Lock - Driver
Passenger Door
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 743
1 - Door Lock Switch - Passenger 2 - Outside Rearview Mirror - Passenger 3 - Door Frame 4 Door Lock - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) Right (AY1) 6 - Window
Switch - Passenger 7 - Window Motor - Passenger
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 744
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock Switch - Driver
Door Lock Switch - Passenger
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 745
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 746
Power Door Lock Switch: Service and Repair
Door Lock Switch Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Power Mirror Switch: Locations
Door Component Views
Driver Door
1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Door Lock Switch - Driver 4 - Window
Switch - Driver 5 - Outside Rearview Mirror Switch 6 - Window Motor - Driver 7 - Inflatable
Restraint Side Impact Sensor (SIS) Left (AY1) 8 - Door Lock - Driver
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 750
Power Mirror Switch: Diagrams
Component Connector End Views - Continued
Outside Rearview Mirror Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 751
Power Mirror Switch: Service and Repair
Power Mirror Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
Power Seat Switch: Locations
Passenger Compartment/Roof Component Views
Driver Seat Components
1 - Seat Recline Motor - Driver (AH5) 2 - Heated Seat Element - Driver - Back (KA1) 3 - Seat
Adjuster Switch - Driver 4 - Heated Seat Control Module (KA1) 5 - Horizontal Motor (Part of the
Seat Adjuster Motor Assembly - Driver) 6 - Front Vertical Motor (Part of the Seat Adjuster Motor
Assembly - Driver) 7 - Rear Vertical Motor (Part of the Seat Adjuster Motor Assembly - Driver) 8 Heated Seat Element - Driver - Seat (KA1)
Passenger Seat Components
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 755
1 - Heated Seat Element - Passenger - Back (KA1) 2 - Seat Belt Switch - Passenger 3 - Seat Belt
Tension Sensor - Passenger 4 - Seat Belt Tension Sensor - Passenger, Connector 5 - Rear
Vertical Motor (Part of the Seat Adjuster Motor Assembly - Passenger) 6 - Front Vertical Motor
(Part of the Seat Adjuster Motor Assembly - Passenger) 7 - Horizontal Motor (Part of the Seat
Adjuster Motor Assembly - Passenger) 8 - Inflatable Restraint Front Passenger Presence System
(PPS) Module 9 - Inflatable Restraint Front Passenger Presence System (PPS) Sensor 10 - Seat
Adjuster Switch - Passenger (AG2) 11 - Heated Seat Element - Passenger - Seat (KA1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 756
Power Seat Switch: Diagrams
Component Connector End Views - Continued
Seat Adjuster Switch - Driver (AG1)
Seat Adjuster Switch - Driver (AH5)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 757
Seat Adjuster Switch - Passenger (AG2)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
(Impala)
Power Seat Switch: Service and Repair Driver Seat and Passenger Seat Adjuster Switch Knob
Replacement (Impala)
Driver Seat and Passenger Seat Adjuster Switch Knob Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
(Impala) > Page 760
Power Seat Switch: Service and Repair Power Seat Switch Replacement (Impala)
Power Seat Switch Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Seat Heater Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel
1 - Headlamp Switch 2 - Instrument Panel Cluster (IPC) 3 - Inflatable Restraint Steering Wheel
Module Coil 4 - Driver Information Center (DIC) Switch 5 - Ambient Light Sensor 6 - Inflatable
Restraint Passenger Air Bag On/Off Indicator (without 9C1/9C3) 7 - Radio 8 - Inflatable Restraint
Instrument Panel Module 9 - Instrument Panel Trim Panel 10 - Heated Seat Switch - Passenger
(KA1) 11 - HVAC Control Module 12 - Heated Seat Switch - Driver (KA1) 13 - Turn
Signal/Multifunction Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Headliner Components
1 - Headliner 2 - Dome/Reading Lamps 3 - Garage Door Opener (UG1) 4 - Sunroof Switch (CF5)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 767
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views - Continued
Sunroof Switch (CF5)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 768
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 773
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views
Brake Booster Vacuum Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views > Page 778
Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Rear of Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views > Page 779
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 780
Brake Booster Vacuum Sensor: Diagrams
Component Connector End Views
Brake Booster Vacuum Sensor (LZG, LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 781
Brake Booster Vacuum Sensor: Service and Repair
Power Brake Booster Vacuum Sensor Replacement
Removal Procedure
1. Disconnect the brake booster vacuum sensor electrical connector.
2. Remove the brake booster vacuum sensor (1) from the booster. 3. Remove the brake booster
vacuum sensor grommet (2) from the booster.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 782
1. Install the brake booster vacuum sensor grommet (2) to the booster. 2. Install the brake booster
vacuum sensor (1) to the booster.
3. Connect the brake booster vacuum sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Powertrain Component Views
Brake Fluid Level Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Powertrain Component Views > Page 787
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Rear of Engine Compartment
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Right Front of the Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Powertrain Component Views > Page 788
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 789
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 790
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from brake fluid level sensor.
2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining
tabs on the end of the brake fluid level sensor (1) and
press the sensor through the reservoir to remove.
Installation Procedure
1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor
retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations
Parking Brake Release Switch: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Page 794
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. Refer to
Front Carpet Retainer Replacement (Impala) . 3. Disconnect the electrical connector from the
switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1).
Installation Procedure
1. Install the parking brake indicator switch (1).
Notice: Refer to Fastener Notice .
2. Install the mounting screw.
Tighten the mounting screw to 3 N.m (26 lb in).
3. Connect the electrical connector to the switch.
Check the operation of the switch.
4. Install the left carpet retainers. Refer to Front Carpet Retainer Replacement (Impala) . 5. Install
the left side instrument panel insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Service and Repair
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-05-25-004A > Oct > 08 >
ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: Customer Interest ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052
Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-05-25-004A > Oct > 08 >
ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 809
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-05-25-004A >
Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - ABS/TCS Lamps ON/DTC's
C0035-C0052 Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-05-25-004A >
Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 815
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated
Rear Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Window
Noise When Operated
TECHNICAL
Bulletin No.: 06-08-64-033C
Date: April 29, 2008
Subject: Rubbing/Squealing/Grinding Noise When Door Glass Is Raised Or Lowered, Scratches in
Door Glass (Replace Door Glass Belt Sealing Strip)
Models: 2006-2008 Chevrolet Impala
Built Prior to November 2007
Supercede:
This bulletin is being revised to update the model years and add the build date. Please discard
Corporate Bulletin Number 06-08-64-033B (Section 08 - Body & Accessories).
Condition
Some customers may comment on a rubbing, squealing or grinding noise when opening or closing
the left or right front or rear door glass. They may also comment of scratches in the door glass.
Cause
This condition may be cause by dirt accumulating on the lip of the belt sealing strip.
Correction
Replace the door glass outer belt sealing strip with a newly designed outer belt sealing strip . Refer
to Front Side Door Window Belt Outer Sealing Strip Replacement or Rear Side Door Window Belt
Outer Sealing Strip Replacement in SI. Clean the glass with glass cleaner and if scuffs or scratches
are found it may be necessary to replace the glass as well.
Parts Information
Warranty Information
For vehicle repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 821
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 827
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 828
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Right Rear Wheel Speed Sensor (Left Similar)
1 - Wheel Speed Sensor (WSS) - Right Rear (Wheel Speed Sensor (WSS) - Left Rear Similar)
Right Front Wheel Speed Sensor (Left Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 829
1 - Wheel Speed Sensor (WSS) Connector - Right Front (Wheel Speed Sensor (WSS) Connector Left Front Similar) 2 - Wheel Speed Sensor (WSS) - Right Front (Wheel Speed Sensor (WSS) Left Front Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 830
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor (WSS) - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Left Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 831
Wheel Speed Sensor (WSS) - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Right Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 832
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures
Yaw Rate Sensor: Procedures
Yaw Rate Reference Table Resetting
Circuit Description
Optimum vehicle stability enhancement system (VSES) function is dependant on many variables.
The characteristics of a specific vehicle, that affect vehicle handling or input signals to the
electronic brake control module (EBCM), ultimately determine how the VSES operates. The basic
EBCM software must be fine tuned as the vehicle is operated. This logic is referred to as adaptive
learning.
Adaptive learning is accomplished by maintaining a yaw rate sensor/lateral accelerometer data
table in the EBCM memory. As the vehicle is operated, the table is populated with data that is later
referenced, and sometimes modified, to allow the EBCM to provide the best possible stability
control for the specific vehicle.
Important: If the data in the yaw rate sensor/lateral accelerometer data table becomes unreliable,
false activations of the VSES, poor VSES performance or false setting of DTC C0186 or C0196
may result.
A replacement EBCM may have some unreliable data stored in the yaw rate sensor/lateral
accelerometer data table. For this reason, it is important to perform the yaw rate reference table
reset procedure after replacing the EBCM.
Replacement of the yaw rate sensor/lateral accelerometer or the installation of different size tires
may also the data stored in the table to become unreliable. Therefore, the yaw rate reference table
reset procedure must be performed.
This procedure is to be used only for vehicles equipped with VSES (JL4).
1. Turn OFF the ignition. 2. Disconnect the yaw rate sensor/lateral accelerometer harness
connector. 3. Start the engine. 4. Apply firm and steady pressure to the brake pedal for at least 10
seconds. 5. Turn OFF the ignition. 6. Reconnect the yaw rate sensor/lateral accelerometer harness
connector. 7. Turn ON the ignition and use the scan tool to clear the DTCs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures > Page 837
Yaw Rate Sensor: Removal and Replacement
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures > Page 838
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 849
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 850
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 851
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 852
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 858
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 859
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
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Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 860
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
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Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 861
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
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Service Bulletins > Page 862
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Service Bulletins > Page 863
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
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Service Bulletins > Page 864
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
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Service Bulletins > Page 865
1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions
Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Diagram Information and Instructions > Page 870
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Diagram Information and Instructions > Page 871
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Diagram Information and Instructions > Page 872
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 873
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 874
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 875
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 876
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 877
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 878
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 879
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 880
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 881
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Diagram Information and Instructions > Page 882
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 883
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 884
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 885
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 886
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 887
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Diagram Information and Instructions > Page 888
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Diagram Information and Instructions > Page 889
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 890
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 891
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 892
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 893
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 894
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 895
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Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 896
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Diagram Information and Instructions > Page 897
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Diagram Information and Instructions > Page 898
Radiator Cooling Fan Temperature Sensor / Switch: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagram Information and Instructions > Page 899
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Diagram Information and Instructions > Page 900
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Diagram Information and Instructions > Page 901
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagram Information and Instructions > Page 902
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Diagram Information and Instructions > Page 982
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Diagram Information and Instructions > Page 987
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 989
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Diagram Information and Instructions > Page 990
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagram Information and Instructions > Page 992
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 993
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 994
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 995
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 996
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Locations
Oil Level Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Locations > Page 1001
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Locations > Page 1002
Oil Level Sensor: Diagrams
Component Connector End Views
Engine Oil Level Switch (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Locations > Page 1003
Oil Level Sensor: Service and Repair
Engine Oil Level Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Drain the oil from the
oil pan. 3. Disconnect the oil level sensor electrical connector.
4. Remove the oil level sensor bolt (751). 5. Remove the oil level sensor (727) and O-ring (728)
from the oil pan.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Locations > Page 1004
1. Install the oil level sensor (727) and O-ring (728) to the oil pan.
Notice: Refer to Fastener Notice .
2. Install the oil level sensor bolt (751).
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the oil level sensor electrical connector. 4. Lower the vehicle. 5. Refill the engine oil to
the proper level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Locations
Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Locations > Page 1008
15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Locations > Page 1009
Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Locations > Page 1010
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Locations > Page 1011
1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front of Vehicle/Engine Compartment Component Views
Under the Hood Latch Trim Panel
1 - Ambient Air Temperature Sensor 2 - Hood Ajar Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 1016
Ambient Temperature Sensor / Switch HVAC: Diagrams
Component Connector End Views
Ambient Air Temperature Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 1017
Ambient Temperature Sensor / Switch HVAC: Service and Repair
Ambient Air Temperature Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Powertrain Component Views
Refrigerant Pressure Sensor / Switch: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Powertrain Component Views > Page 1022
Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 1023
Refrigerant Pressure Sensor / Switch: Diagrams
Component Connector End Views
A/C Refrigerant Pressure Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 1024
Refrigerant Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Remove the air cleaner assembly. 2. Disconnect the electrical connector from the A/C refrigerant
pressure sensor.
3. Remove the A/C refrigerant pressure sensor from the evaporator tube.
Installation Procedure
1. Replace the O-ring seal for the A/C refrigerant pressure sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 1025
Notice: Refer to Fastener Notice.
2. Install the A/C refrigerant pressure sensor to the evaporator tube.
Tighten the sensor to 4.7 N.m (41 lb in).
3. Connect the electrical connector to the A/C refrigerant pressure sensor. 4. Install the air cleaner
assembly. 5. Leak test the fittings of the component using J 39400-A.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake
Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. Refer to
Front Carpet Retainer Replacement (Impala) . 3. Disconnect the electrical connector from the
switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1).
Installation Procedure
1. Install the parking brake indicator switch (1).
Notice: Refer to Fastener Notice .
2. Install the mounting screw.
Tighten the mounting screw to 3 N.m (26 lb in).
3. Connect the electrical connector to the switch.
Check the operation of the switch.
4. Install the left carpet retainers. Refer to Front Carpet Retainer Replacement (Impala) . 5. Install
the left side instrument panel insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations
Ambient Light Sensor: Locations
Instrument Panel/Center Console Component Views
Instrument Panel
1 - Headlamp Switch 2 - Instrument Panel Cluster (IPC) 3 - Inflatable Restraint Steering Wheel
Module Coil 4 - Driver Information Center (DIC) Switch 5 - Ambient Light Sensor 6 - Inflatable
Restraint Passenger Air Bag On/Off Indicator (without 9C1/9C3) 7 - Radio 8 - Inflatable Restraint
Instrument Panel Module 9 - Instrument Panel Trim Panel 10 - Heated Seat Switch - Passenger
(KA1) 11 - HVAC Control Module 12 - Heated Seat Switch - Driver (KA1) 13 - Turn
Signal/Multifunction Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 1037
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel
1 - Headlamp Switch 2 - Instrument Panel Cluster (IPC) 3 - Inflatable Restraint Steering Wheel
Module Coil 4 - Driver Information Center (DIC) Switch 5 - Ambient Light Sensor 6 - Inflatable
Restraint Passenger Air Bag On/Off Indicator (without 9C1/9C3) 7 - Radio 8 - Inflatable Restraint
Instrument Panel Module 9 - Instrument Panel Trim Panel 10 - Heated Seat Switch - Passenger
(KA1) 11 - HVAC Control Module 12 - Heated Seat Switch - Driver (KA1) 13 - Turn
Signal/Multifunction Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations > Page 1041
Combination Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations > Page 1042
Turn Signal/Multifunction Switch X3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Headlamp Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel
1 - Headlamp Switch 2 - Instrument Panel Cluster (IPC) 3 - Inflatable Restraint Steering Wheel
Module Coil 4 - Driver Information Center (DIC) Switch 5 - Ambient Light Sensor 6 - Inflatable
Restraint Passenger Air Bag On/Off Indicator (without 9C1/9C3) 7 - Radio 8 - Inflatable Restraint
Instrument Panel Module 9 - Instrument Panel Trim Panel 10 - Heated Seat Switch - Passenger
(KA1) 11 - HVAC Control Module 12 - Heated Seat Switch - Driver (KA1) 13 - Turn
Signal/Multifunction Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 1046
Headlamp Switch: Diagrams
Component Connector End Views
Headlamp Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 1047
Headlamp Switch: Service and Repair
Headlamp Switch Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
Horn Switch: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Steering Wheel 2 - Steering Wheel Control Switch - Right 3 - Steering Wheel Control Switch Left 4 - Horn Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations > Page 1051
Horn Switch: Diagrams
Component Connector End Views - Continued
Horn Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations > Page 1052
Horn Switch: Service and Repair
Steering Wheel Horn Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel
1 - Headlamp Switch 2 - Instrument Panel Cluster (IPC) 3 - Inflatable Restraint Steering Wheel
Module Coil 4 - Driver Information Center (DIC) Switch 5 - Ambient Light Sensor 6 - Inflatable
Restraint Passenger Air Bag On/Off Indicator (without 9C1/9C3) 7 - Radio 8 - Inflatable Restraint
Instrument Panel Module 9 - Instrument Panel Trim Panel 10 - Heated Seat Switch - Passenger
(KA1) 11 - HVAC Control Module 12 - Heated Seat Switch - Driver (KA1) 13 - Turn
Signal/Multifunction Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 1056
Turn Signal Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 1057
Turn Signal/Multifunction Switch X3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Removal Procedure
Caution: Refer to SIR Caution .
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Remove the upper and lower
trim covers. Refer to Steering Column Trim Covers Replacement (See: Steering and
Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Covers Replacement) .
Important: The abrasion sleeve located on the steering column wire harness assembly must be
reinstalled. Make note of what connector is coming out of the abrasion sleeve for installation
purposes.
3. Remove the wire harness assembly (1) from the wire harness strap (2). 4. Disconnect the turn
signal and multifunction switch assembly connector from the SIR system coil connector.
5. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly out of the
bulkhead connector (1).
6. Remove the 2 pan head tapping screws (1) and (3) from the turn signal and multifunction switch
assembly (2). 7. Remove the turn signal and multifunction switch assembly (2) from the steering
column tilt head assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1060
Installation Procedure
1. Install the turn signal and multifunction switch assembly (2) onto the steering column tilt head
assembly.
Notice: Refer to Fastener Notice .
Important: Be sure that the electrical contact of the turn signal and multifunction switch assembly
(2) rests on the turn signal cancel cam assembly.
2. Screw the 2 pan head tapping screws (1) and (3) into the turn signal and multifunction assembly
(2).
Tighten the pan head tapping screws (1) and (3) to 1 N.m (11 lb in).
3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly into the bulkhead
connector (1).
4. Connect the turn signal and multifunction switch assembly connector to the SIR coil connector.
Important: The abrasion sleeve must be installed back onto the steering column wire harness
assembly. The ignition lock cylinder case wires and connector must be hanging out of the middle of
the abrasion sleeve.
5. Install the wire harness assembly (1) into the wire harness strap (2). 6. Install the upper and
lower trim covers. Refer to Steering Column Trim Covers Replacement (See: Steering and
Suspension/Steering/Steering
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1061
Column/Service and Repair/Steering Column Trim Covers Replacement) .
7. Enable the SIR system. Refer to SIR Disabling and Enabling .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1062
Turn Signal Switch: Service and Repair Turn Signal Switch Housing Replacement
Turn Signal Switch Housing Replacement
Removal Procedure
Caution: Refer to SIR Caution .
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Remove the tilt head
components. Refer to Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Cancel Cam and Steering
Shaft Upper Bearing Spring Replacement) .
3. Remove the turn signal and multifunction switch assembly only. Refer to Turn Signal
Multifunction Switch Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement) .
4. Slide the turn signal switch housing off of the steering column shaft assembly.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1063
Important: The switch mounting bracket must be pressed firmly against the steering column tilt
head.
1. Slide the turn signal switch housing onto the steering column shaft assembly. 2. Install the turn
signal and multifunction switch assembly only. Refer to Turn Signal Multifunction Switch
Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Multifunction Switch
Replacement) .
3. Install the tilt head components. Refer to Turn Signal Cancel Cam and Steering Shaft Upper
Bearing Spring Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Turn Signal Cancel Cam and Steering
Shaft Upper Bearing Spring Replacement) .
4. Enable the SIR system. Refer to SIR Disabling and Enabling .
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Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
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Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
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1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
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Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
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Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
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Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Information and Instructions > Page 1256
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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Information and Instructions > Page 1272
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 1345
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1346
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1347
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1348
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Information and Instructions > Page 1349
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1350
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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1351
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1352
1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
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Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1361
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
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Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1362
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
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Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1363
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1364
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
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10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1370
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
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10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1371
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
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7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
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Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
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Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
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1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1510
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
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Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315
See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
Powertrain Component Views
Fuel Pump and Sender Assembly
1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
1. Remove the fuel sender assembly. 2. Using two flat-bladed tools, carefully pull both locking tabs
(1) outward while simultaneously lifting the level sensor.
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3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
Installation Procedure
1. Push in the electrical terminals (1) and ensure the terminals are secure.
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2. Carefully insert the level sensor until the locking tabs (1) snap into the locking position. 3. Install
the fuel sender assembly.
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Fuel Tank Pressure Sensor: Locations
Powertrain Component Views
Fuel Tank Components
1 - Fuel Tank 2 - Fuel Pump and Sender Assembly 3 - Fuel Tank Pressure (FTP) Sensor 4 Evaporative Emission (EVAP) Canister Vent Solenoid Valve
Fuel Pump and Sender Assembly
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1525
1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
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Powertrain Component Views
Intake Air Temperature Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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and Instructions > Page 1659
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1668
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1669
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1670
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
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5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
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2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
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6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Top of Engine (LS4)
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Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1 15 - Fuel Injector 2 16 - Ignition
Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6
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20 - Ignition Coil 6
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Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LS4)
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Page 1683
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor
electrical connector (2).
3. Remove the MAP sensor (714) from the intake manifold. 4. Remove the MAP sensor grommet
(715), if required.
Installation Procedure
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Page 1684
1. Lubricate the MAP sensor grommet with clean engine oil, if required. 2. Install the MAP sensor
grommet (715), if required. 3. Install the MAP sensor (714).
4. Connect the MAP sensor electrical connector (2). 5. Install the engine sight shield.
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Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
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15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
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Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
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Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
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1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
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Recalls for Oxygen Sensor: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: Recalls Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
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1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Oxygen Sensor: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: All Technical Service Bulletins Campaign - Inspect/Replace Post-Catalyst O2
Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
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Technical Service Bulletins for Oxygen Sensor: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
> Page 1707
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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> Page 1708
Disclaimer
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Page 1709
Oxygen Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Underbody
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1 - Heated Oxygen Sensor (HO2S) 2
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Oxygen Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 1840
Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LS4)
Heated Oxygen Sensor (HO2S) 2
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Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Oxygen and Oxygen Sensor Notice > Page 1844
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
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Oxygen and Oxygen Sensor Notice > Page 1845
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
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Oxygen and Oxygen Sensor Notice > Page 1846
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
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Oxygen and Oxygen Sensor Notice > Page 1847
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
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Oxygen and Oxygen Sensor Notice > Page 1848
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
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Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Remove the intake manifold sight shield. 2. Remove the connector position assurance (CPA)
retainer (1). 3. Disconnect the bank 1 sensor 1 electrical connector (2).
4. Remove the bank 1 sensor 1 from the exhaust manifold.
Installation Procedure
Important: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before reinstallation.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 1851
1. If re-installing the old sensor, coat the threads with anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 1 sensor 1 to the exhaust manifold.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 1 sensor 1 electrical connector (2). 4. Install the CPA retainer (1). 5. Install the
intake manifold sight shield.
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Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position
assurance (CPA) retainer. 3. Disconnect the bank 2 sensor 2 electrical connector.
4. Remove the bank 2 sensor 2 from the catalytic converter.
Installation Procedure
Important: A special anti-seize compound is use on the heated oxygen sensor (HO2S) threads.
The compound consists of liquid graphite and glass beads. The graphite tends to burns away, but
the glass beads remain, making the sensor easier to remove. New or service replacement sensors
already have the compound applied to the threads. If the sensor is removed from an exhaust
component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize
compound applied before reinstallation.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 1853
1. If re-installing the old sensor, coat the threads with the anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 2 sensor 2 to the catalytic converter.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 2 sensor 2 electrical connector. 4. Install the CPA retainer. 5. Lower the
vehicle.
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information and Instructions > Page 1880
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Information and Instructions > Page 1953
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 1974
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Information and Instructions > Page 1975
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 1976
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1979
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 1980
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1981
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1982
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1983
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Information and Instructions > Page 1984
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > 4T65-E Automatic Transaxle
Vehicle Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Vehicle Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
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Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
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Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair
).
3. Disconnect the vehicle speed sensor (VSS) electrical connector.
4. Remove the VSS bolt (9). 5. Remove the VSS (10) from the extension case.
6. Remove the O-ring (11) from the VSS (10).
Installation Procedure
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1. Install the O-ring (11) to the VSS (10).
2. Install the VSS (10).
Notice: Refer to Fastener Notice .
3. Install the VSS bolt (9).
Tighten the bolt (9) to 12 N.m (106 lb in).
4. Connect the VSS electrical connector. 5. Install the right front tire and wheel. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6.
Lower the vehicle.
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
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Page 1997
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Page 1998
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
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Page 1999
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
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Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Component Views > Page 2004
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Component Views > Page 2005
Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Instructions > Page 2362
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft
Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315
See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
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2546
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
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> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
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7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
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are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
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Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
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cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
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22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
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Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
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7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
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3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
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7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
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Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Page 2691
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
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5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
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2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
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6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Component Information > Locations > Passenger Compartment/Roof Component Views
Impact Sensor: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Passenger Seat Components
1 - Heated Seat Element - Passenger - Back (KA1) 2 - Seat Belt Switch - Passenger 3 - Seat Belt
Tension Sensor - Passenger 4 - Seat Belt Tension Sensor - Passenger, Connector 5 - Rear
Vertical Motor (Part of the Seat Adjuster Motor Assembly - Passenger) 6 - Front Vertical Motor
(Part of the Seat Adjuster Motor Assembly - Passenger) 7 - Horizontal Motor (Part of the Seat
Adjuster Motor Assembly - Passenger) 8 - Inflatable Restraint Front Passenger Presence System
(PPS) Module 9 - Inflatable Restraint Front Passenger Presence System (PPS) Sensor 10 - Seat
Adjuster Switch - Passenger (AG2) 11 - Heated Seat Element - Passenger - Seat (KA1)
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Impact Sensor: Locations Door Component Views
Door Component Views
Driver Door
1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Door Lock Switch - Driver 4 - Window
Switch - Driver 5 - Outside Rearview Mirror Switch 6 - Window Motor - Driver 7 - Inflatable
Restraint Side Impact Sensor (SIS) Left (AY1) 8 - Door Lock - Driver
Passenger Door
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1 - Door Lock Switch - Passenger 2 - Outside Rearview Mirror - Passenger 3 - Door Frame 4 Door Lock - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) Right (AY1) 6 - Window
Switch - Passenger 7 - Window Motor - Passenger
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Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Right Front of the Engine Compartment
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1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Impact Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Right Front of the Engine Compartment
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1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Impact Sensor: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Front End Sensor - Left
Inflatable Restraint Front End Sensor - Right
Inflatable Restraint Front Passenger Presence System (PPS) Sensor
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Component Information > Locations > Page 2710
Inflatable Restraint Side Impact Sensor (SIS) - Left (AY1)
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Inflatable Restraint Side Impact Sensor (SIS) Right (AY1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement (Impala)
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Impala)
Inflatable Restraint Side Impact Sensor Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement (Impala) > Page 2714
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations
Seat Belt Buckle Switch: Locations
Passenger Compartment/Roof Component Views
Left Front Seat of the Vehicle
1 - Seat Belt Switch - Driver
Front Seat Airbag Inlines
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2718
1 - Seat Belt Switch-Passenger 2 - Passenger 3 - X314 4 - Seat Belt Switch-Driver 5 - Inflatable
Restraint Side Impact Module-Left 6 - X312 7 - Driver Seat 8 - Inflatable Restraint Side Impact
Module-Right
Passenger Seat Components
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2719
1 - Heated Seat Element - Passenger - Back (KA1) 2 - Seat Belt Switch - Passenger 3 - Seat Belt
Tension Sensor - Passenger 4 - Seat Belt Tension Sensor - Passenger, Connector 5 - Rear
Vertical Motor (Part of the Seat Adjuster Motor Assembly - Passenger) 6 - Front Vertical Motor
(Part of the Seat Adjuster Motor Assembly - Passenger) 7 - Horizontal Motor (Part of the Seat
Adjuster Motor Assembly - Passenger) 8 - Inflatable Restraint Front Passenger Presence System
(PPS) Module 9 - Inflatable Restraint Front Passenger Presence System (PPS) Sensor 10 - Seat
Adjuster Switch - Passenger (AG2) 11 - Heated Seat Element - Passenger - Seat (KA1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2720
Seat Belt Buckle Switch: Diagrams
Component Connector End Views - Continued
Seat Belt Switch - Driver
Seat Belt Switch - Passenger
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension
Sensor > Component Information > Locations
Seat Belt Tension Sensor: Locations
Passenger Compartment/Roof Component Views
Passenger Seat Components
1 - Heated Seat Element - Passenger - Back (KA1) 2 - Seat Belt Switch - Passenger 3 - Seat Belt
Tension Sensor - Passenger 4 - Seat Belt Tension Sensor - Passenger, Connector 5 - Rear
Vertical Motor (Part of the Seat Adjuster Motor Assembly - Passenger) 6 - Front Vertical Motor
(Part of the Seat Adjuster Motor Assembly - Passenger) 7 - Horizontal Motor (Part of the Seat
Adjuster Motor Assembly - Passenger) 8 - Inflatable Restraint Front Passenger Presence System
(PPS) Module 9 - Inflatable Restraint Front Passenger Presence System (PPS) Sensor 10 - Seat
Adjuster Switch - Passenger (AG2) 11 - Heated Seat Element - Passenger - Seat (KA1)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension
Sensor > Component Information > Locations > Page 2724
Seat Belt Tension Sensor: Diagrams
Component Connector End Views - Continued
Seat Belt Tension Sensor - Passenger
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information >
Page 2729
Seat Occupant Sensor: Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081
Code Clearing
Bulletin No.: 07-09-41-004
Date: June 13, 2007
INFORMATION
Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and
Diagnostic Module (SDM) DTCs B0071, B0074, B0081
Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade,
Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008
Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon
XL Denali
A condition exists where the passenger presence system (PPS) may continue to output a fault to
the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue
to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in
the SDM.
If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the
codes.
With the Ignition OFF, open and close the driver door.
With a scan tool, clear PPS DTC (B0071 or B0074).
While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate
any functions in the vehicle during this time.
Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary
repair. With the scan tool, clear DTC B0081.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 2730
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 2731
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Powertrain Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Powertrain Component Views > Page 2737
Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2738
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2739
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2740
Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Locations > Page 2745
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2748
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2749
are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2750
Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2751
cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2752
22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2753
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2754
7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2755
3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2756
7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Removal Procedure
Caution: Refer to SIR Caution .
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Remove the steering column
from the vehicle. Refer to Steering Column Replacement (See: Steering and
Suspension/Steering/Steering
Column/Service and Repair/Steering Column Replacement) .
3. Remove the following from the steering shaft:
1. The boot seal (5) 2. The steering shaft seal (4) 3. The sensor retainer (3) 4. The sensor locator
(2)
4. Remove the steering wheel position sensor (1). Refer to Steering Wheel Position Sensor
Centering (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Position Sensor
Centering) .
5. Remove the adapter and bearing assembly from the steering jacket assembly.
Installation Procedure
1. Install the adapter and bearing assembly to the steering jacket assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2763
2. Install the following onto the steering shaft:
1. The steering wheel position sensor (1)-Refer to Steering Wheel Position Sensor Centering (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Wheel Position Sensor Centering) .
2. The sensor locator (2) 3. The sensor retainer (3) 4. The steering shaft seal (4) 5. The boot seal
(5)
3. Install the steering column into the vehicle. Refer to Steering Column Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Replacement) .
4. Enable the SIR system. Refer to SIR Disabling and Enabling .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2764
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2765
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2766
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2767
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2768
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2769
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft
Lower Bearing Replacement
Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement
Removal Procedure
Caution: Refer to SIR Caution .
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Remove the steering column
from the vehicle. Refer to Steering Column Replacement (See: Steering and
Suspension/Steering/Steering
Column/Service and Repair/Steering Column Replacement) .
3. Remove the following from the steering shaft:
1. The boot seal (5) 2. The steering shaft seal (4) 3. The sensor retainer (3) 4. The sensor locator
(2)
4. Remove the steering wheel position sensor (1). Refer to Steering Wheel Position Sensor
Centering (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Position Sensor
Centering) .
5. Remove the adapter and bearing assembly from the steering jacket assembly.
Installation Procedure
1. Install the adapter and bearing assembly to the steering jacket assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2775
2. Install the following onto the steering shaft:
1. The steering wheel position sensor (1)-Refer to Steering Wheel Position Sensor Centering (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Wheel Position Sensor Centering) .
2. The sensor locator (2) 3. The sensor retainer (3) 4. The steering shaft seal (4) 5. The boot seal
(5)
3. Install the steering column into the vehicle. Refer to Steering Column Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Replacement) .
4. Enable the SIR system. Refer to SIR Disabling and Enabling .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2776
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering
Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2777
11. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
15. From the technicians point of view, the FRONT of the sensor will have:
* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
20. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (3)
* A pin hole (1) for the centering pin-Note the location of the pin hole.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2778
21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing
assembly. 23. To install the sensor, proceed to step 17 in the installation procedure.
24. From the technicians point of view, the FRONT of the sensor will have:
* A flush rotor flange cuff (4)
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* An alignment mark (3) on the flush rotor flange cuff (4) for installation
* A foam ring (1)
25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing
assembly. 27. To install the sensor, proceed to step 21 in the installation procedure.
Installation Procedure
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
5. From the technicians point of view, the FRONT of the sensor will have:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2779
* A foam ring (4)
* A pin hole (7) for the centering pin-Note the location of the pin hole.
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 8. Install the connector to the sensor.
9. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A raised rotor flange cuff (5)
* An alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 12. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2780
13. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A raised rotor flange cuff (4)
* An alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 16. Install the connector to the sensor.
17. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (2) for the centering pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
* An alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 20. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor or Steering Shaft Lower Bearing Replacement > Page 2781
21. From the technicians point of view, the FRONT of the sensor will have:
* A pin hole (3) for the centering pin-Note location of the pin hole.
* A flush rotor flange cuff (5)
* An alignment mark (4) for installation
* A foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* An alignment tab (2) for installing into the adapter and bearing assembly
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.
23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 24. Install the connector to the sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2787
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2788
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2789
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2790
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2791
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2792
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement (Snap In Style)
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service
and Repair) .
3. Dismount the tire from the rim. Refer to Tire Mounting and Dismounting (See:
Maintenance/Wheels and Tires/Tires/Service and Repair/Removal
and Replacement) .
Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure
monitor (TPM) and a new TORX screw during installation.
4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire
pressure valve stem (3).
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
5. Remove the tire pressure valve stem by pulling it through the rim.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2793
Notice: Refer to Fastener Notice .
Important: *
Ensure the flat of the valve, lines up with the flats of the snap in the enclosure.
* TPM valves and TORX screws are one-time use only.
1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3).
Tighten the TORX screw to 1.3 N.m (11.5 lb in).
Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base
compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire
or rim deterioration.
2. Apply tire soap to the rubber portion of the valve stem (1).
3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the
valve hole on the rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2794
Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer
needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire
is inflated. The technician can then program the vehicle as normal.
4. Mount the tire to the rim. Refer to Tire Mounting and Dismounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal and
Replacement) .
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and
Repair) .
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Sensor Learn () .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle > Page 2801
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2802
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2803
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2804
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle > Page 2809
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 2810
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle > Page 2815
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2816
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2817
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E Automatic Transaxle > Page 2823
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2824
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid
Temperature Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid
Temperature Sensor Replacement > Page 2827
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and
Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid
Temperature Sensor Replacement > Page 2828
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and
Repair) .
8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Window Switch: >
08-08-110-007 > Mar > 08 > Interior - Driver's Power Window Switch Sticks/Binds
Power Window Switch: Customer Interest Interior - Driver's Power Window Switch Sticks/Binds
TECHNICAL
Bulletin No.: 08-08-110-007
Date: March 31, 2008
Subject: Driver Side Window Switch Sticks (Replace Window Switch Bezel and/or Window Switch)
Models: 2008 Chevrolet Impala
Condition
Some customers may comment that driver side window switch does not operate the window
correctly or the switch sticks.
Cause
This condition may be caused because the bezel trim has excess flashing, causing the switch to
bind in the bezel. Damage to the window switch may result from this condition.
Correction
Replace the bezel and/or window switch. Refer to Front Side Door Window Switch Bezel
Replacement in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Window Switch: >
08-08-110-007 > Mar > 08 > Interior - Driver's Power Window Switch Sticks/Binds
Power Window Switch: All Technical Service Bulletins Interior - Driver's Power Window Switch
Sticks/Binds
TECHNICAL
Bulletin No.: 08-08-110-007
Date: March 31, 2008
Subject: Driver Side Window Switch Sticks (Replace Window Switch Bezel and/or Window Switch)
Models: 2008 Chevrolet Impala
Condition
Some customers may comment that driver side window switch does not operate the window
correctly or the switch sticks.
Cause
This condition may be caused because the bezel trim has excess flashing, causing the switch to
bind in the bezel. Damage to the window switch may result from this condition.
Correction
Replace the bezel and/or window switch. Refer to Front Side Door Window Switch Bezel
Replacement in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2843
Power Window Switch: Locations
Door Component Views
Driver Door
1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Door Lock Switch - Driver 4 - Window
Switch - Driver 5 - Outside Rearview Mirror Switch 6 - Window Motor - Driver 7 - Inflatable
Restraint Side Impact Sensor (SIS) Left (AY1) 8 - Door Lock - Driver
Passenger Door
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2844
1 - Door Lock Switch - Passenger 2 - Outside Rearview Mirror - Passenger 3 - Door Frame 4 Door Lock - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) Right (AY1) 6 - Window
Switch - Passenger 7 - Window Motor - Passenger
Left Rear Door
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2845
1 - Door Frame 2 - Window Switch - Left Rear 3 - Window Motor - Left Rear 4 - Door Lock - Left
Rear
Right Rear Door
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2846
1 - Window Switch - Right Rear 2 - Door Frame 3 - Door Lock - Right Rear 4 - Window Motor Right Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2847
Power Window Switch: Diagrams
Component Connector End Views - Continued
Window Switch - Driver X1
Window Switch - Driver X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2848
Window Switch - Left Rear
Window Switch - Passenger
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2849
Window Switch - Right Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Technical Service Bulletins > Page 2850
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement
Front Side Door Window Switch Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 2853
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Powertrain Component Views
Washer Fluid Level Switch: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Powertrain Component Views > Page 2859
Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 2860
Washer Fluid Level Switch: Diagrams
Component Connector End Views - Continued
Windshield Washer Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 2861
Washer Fluid Level Switch: Service and Repair
Windshield Washer Solvent Level Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications
Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications
WARRANTY ADMINISTRATION
Bulletin No.: 05-03-07-009C
Date: December 09, 2010
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks
Supercede: This bulletin is being extensively revised to provide technicians and warranty
administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF
WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT
SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension).
Purpose
The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors'
warranty service requirements and recommendations for customer concerns related to wheel
alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel
Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty
service.
Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING
YOUR NEXT GM WHEEL ALIGNMENT SERVICE.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a
successful wheel alignment service.
1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension
and steering configurations. Vehicles
modified in any of these areas are not covered for wheel alignment warranty.
2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is
within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for
labor operations E2000 and E2020.
The following information must be documented or attached to the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the
appropriate calibration maintenance schedules.
Important If it is determined that a wheel alignment is necessary under warranty, use the proper
labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel
Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for
other component repairs is to be charged to the component that causes a wheel alignment
operation.).
The following flowchart is to help summarize the information detailed in this bulletin and should be
used whenever a wheel alignment is performed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2867
Verify Original Equipment Condition of the Vehicle
- Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are
on the vehicle.
- Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have
NOT been done to the vehicle.
- Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision
damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles,
suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact.
- Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving
may show up by looking at the tires and condition of the vehicle.
- Check for other additional equipment items that may significantly affect vehicle mass such as
large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in
trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and
wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed
semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of
these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with
equipment such as the above.)
Customer Concerns, "Normal Operation" Conditions and "Mileage Policy"
Possible Concerns
The following are typical conditions that may require wheel alignment warranty service:
1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of
effort required at the steering wheel to maintain the
vehicle's straight heading."
Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle
Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull
concerns can be due to road crown or road slope, tires, wheel alignment or even in rare
circumstances a steering gear issue. Lead/pull concerns due to road crown are considered
"Normal Operation" and are NOT a warrantable condition -- the customer should be advised that
this is "Normal Operation."
Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a
level condition. If so, this is more likely a "steering wheel angle" concern because the customer is
"steering" the vehicle to obtain a "level" steering wheel.
2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined
as the steering wheel angle (clocking)
deviation from "level" while maintaining a straight heading on a typical straight road.
3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the
shoulders of tires is NOT considered unusual and
should even out with a tire rotation; if the customer is concerned about a "feathering" condition of
the tires, the customer could be advised to rotate the tires earlier than the next scheduled
mileage/maintenance interval (but no later than the next interval). Be sure to understand the
customer's driving habits as this will also heavily influence the tire wear performance; tire wear from
aggressive or abusive driving habits is NOT a warrantable condition.
Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is
"normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can
show evidence of feathering from the factory. These issues do NOT affect the overall performance
and tread life of the tire. Dealer personnel should always check the customer's maintenance
records to ensure that tire inflation pressure is being maintained to placard and that the tires are
being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be
performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2868
Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center
Ribs
Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder
Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear
Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear
Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the
repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center
wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF,
LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life,
etc. A field product report with pictures of the tire wear condition is recommended. Refer to
Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C.
4. Other repairs that affect wheel alignment; e.g., certain component replacement such as
suspension control arm replacement, engine cradle
adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock,
steering knuckle, etc. may require a wheel alignment.
Important If other components or repairs are identified as affecting the wheel alignment, policy calls
for the wheel alignment labor time to be charged to the replaced/repaired component's labor
operation time rather than the wheel alignment labor operations.
Important Vibration type customer concerns are generally NOT due to wheel alignment except in
the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are
NOT to be performed as an investigation/correction for vibration concerns.
"Normal Operation" Conditions
Vehicle Lead/Pull Due to Road Crown or Slope:
As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope.
Be sure to verify from the customer the types of roads they are driving as they may not recognize
the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires
significant steering effort to prevent it from "climbing" the road crown there may be an issue to be
looked into further.
Important
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2869
A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within
"Normal Operation."
Mileage Policy
The following mileage policy applies for E2020 and E2000 labor operations: Note
Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana
Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing
the vehicles.
- 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to
the tie down during shipping, the vehicle's suspension requires some time to reach normal
operating position. For this reason, new vehicles are generally NOT to be aligned until they have
accumulated at least 800 km (500 mi). A field product report should accompany any claim within
this mileage range.
- 801-12,000 km (501-7,500 mi):
- If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle
steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be
apparent early in the life of the vehicle. The following policy applies:
- Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT,
Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and
Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required
- All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above:
E2000/E2020 Claims: Dealer Service Manager Authorization Required
- 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible
for the wheel alignment expense or dealers may provide on a case-by case basis a one-time
customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component
required the use of the subject labor operations, the identified defective component labor operation
will include the appropriate labor time for a wheel alignment as an add condition to the component
repair.
Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN.
Warranty Documentation Requirements
When a wheel alignment service has been deemed necessary, the following items will need to be
clearly documented on/with the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
1. Document the customer concern in as much detail as possible on the repair order and in the
warranty administration system. Preferred examples:
- Steering wheel is off angle in the counterclockwise direction by approximately x degrees or
clocking position.
- Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe,
Moderate or Slight.
- RF and LF tires are wearing on the outside shoulders with severe feathering.
Important In the event of a lead/pull or steering wheel angle concern, please note the direction of
lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the
repair order and within the warranty claim verbatim.
Important In the event of a tire wear concern, please note the position on the vehicle and where the
wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder.
2. Document the technician's findings on cause and correction of the issue. Examples:
- Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees
to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees.
- Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of
+0.30 degrees to 0.00 degrees on the vehicle.
- Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees.
3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the
Repair Order or if print-out capability is not
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2870
available, measurements may also be clearly and legibly handwritten into the Wheel Alignment
Repair Order Questionnaire attached to this bulletin.
4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of
"Before" and "After" wheel alignment measurements to
the Repair Order and retain for use by GM.
Wheel Alignment Equipment and Process
Wheel alignments must be performed with a quality machine that will give accurate results when
performing checks. "External Reference" (image-based camera technology) is preferred. Please
refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment
Requirements and Recommendations.
Requirements:
- Computerized four wheel alignment system.
- Computer capable of printing before and after alignment reports.
- Computer capable of time and date stamp printout.
- Racking system must have jacking capability
- Racking system must be capable of level to 1.6 mm (1/16 in)
- Appropriate wheel stops and safety certification
- Built-in turn plates and slip plates
- Wheel clamps capable of attaching to 20" or larger wheels
- Racking capable of accepting any GM passenger car or light duty truck
- Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations:
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration:
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
- Alignment machines with "internal reference" sensors should be checked (and calibrated, if
necessary) every six months.
- Alignment machines with "external reference" (image-based camera technology) should be
checked (and calibrated, if necessary) once a year.
- Racks must be kept level to within 1.6 mm (1/16 in).
- If any instrument that is part of the alignment machine is dropped or damaged in some way,
check the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Wheel Alignment Process
When performing wheel alignment measurement and/or adjustment, the following steps should be
taken:
Preliminary Steps:
1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels
and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4.
Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for
looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to
stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate
for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's
instructions.
Measure/Adjust:
Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify
that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date
by comparing these to the wheel alignment specifications for the appropriate model and model year
in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments,
irregular and/or premature tire wear and repeat customer concerns
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2871
Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
If necessary, adjust the wheel alignment to vehicle specification and record the before and after
measurements. Refer to Wheel Alignment Specifications in SI.
Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only
source of GM wheel alignment specifications that is kept up-to-date throughout the year.
Test drive vehicle to ensure proper repair.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2872
Frame Angle Measurement (Express / Savana Only) ........
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2873
What corrected the customer concern and was the repair verified?
Please Explain: .............
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications
Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications > Page 2876
Alignment: Specifications Trim Height Specifications
Trim Height Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications > Page 2877
Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description
Alignment: Description and Operation Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2880
Alignment: Description and Operation Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2881
Alignment: Description and Operation Toe Description
Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2882
Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2883
Alignment: Description and Operation
Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2884
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
Thrust Angles Description
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2885
If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be
centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel
alignment.
Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle.
Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle.
If the thrust angle is out of specification, moving the axle to body relationship will change the thrust
angle reading.
If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will
move the thrust angle towards zero degrees.
If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will
move the thrust angle towards zero degrees.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Torque Steer Description
Torque Steer Description
A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the
other direction during deceleration.
The following factors may cause torque steer to be more apparent on a particular vehicle:
* A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front
tires for differences in the brand, the construction, or the size. If the tires appear to be similar,
change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the
most significant effect on torque steer correction.
* A large difference in the right and left front tire pressure
* Left-to-right differences in the front view axle angle may cause significant steering pull in a
vehicle. The pull will be to the side with the most downward sloping axle from the differential to the
wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description > Page 2886
level ground may be used as an indication of bias axle angles. The side with the higher transaxle
pan, shown on the left side of the illustration, has the most downward sloping axle angle.
Memory Steer Description
Memory Steer Description
Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned
the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in
that direction.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2887
Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurements
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause bottoming out over bumps, damage to the suspension components, and symptoms
similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns
and before checking the wheel alignment.
Perform the following before measuring the trim heights:
1. Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle
Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label .
2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the
rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface,
such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured
vertical to the ground. Trim heights should be within 13 mm (0.5 in) to be considered correct.
Z Height Measurement
The Z height dimension measurement determines the proper ride height for the front end of the
vehicle. There is no adjustment procedure. Repair may require replacement of suspension
components.
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands. Let
the vehicle settle. 3. Repeat this operation for a total of 3 times.
Measuring the Z Dimension
4. Measure from the pivot bolt center line down to the lower corner of the lower ball joint in order to
obtain the Z height measurement. 5. Push the front bumper of the vehicle down about 38 mm (1.5
in). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing
operation 2 more times for a total of 3 times. 9. Measure the Z dimension.
10. The true Z height dimension number is the average of the high and the low measurements.
Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height
Specifications) .
D Height Measurement
The D height dimension measurement determines the proper rear end ride height. There is no
adjustment procedure. Repair may require replacement of suspension components.
1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in). 2. Gently
remove your hands.
Allow the vehicle to settle into position.
3. Repeat the jouncing operation 2 more times for a total of 3 times.
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Measuring D Height
4. The D height is measured from a point 30 mm (1.1 in) outboard of the rear brake hose bracket
bolt centerline to the bolt centerline of the trailing
arm to the knuckle attachment.
5. Push the rear bumper downward to 38 mm (1.5 in). 6. Gently remove your hands.
Allow the vehicle to settle into position.
7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height
dimension. 9. The true D height dimension number is the average of the high and the low
measurements. Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height
Specifications) .
10. If these measurements are out of specifications, inspect for the following conditions:
* Improper weight distribution
* Collision damage
* Worn or damaged suspension components
Measuring the P and R Dimension
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2889
Use the following procedure to check the P and R dimensions.
1. Use your hands to lift the front bumper approximately 38 mm (1.59 in). 2. Remove your hands
and allow the vehicle to lower. 3. Use your hands to jounce the front of the vehicle downward
approximately 38 mm (1.59 in). 4. Remove your hands and allow the vehicle to rise. 5. The
dimension (P) for the left and right side of the vehicle is measured from the bottom lip of the wheel
opening to the ground measured at the
center line of the front wheel.
6. Compare the measurement to the specification table. Refer to Trim Height Specifications (See:
Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications) .
7. If the measurement is outside of the specified range, replace the front springs. Refer to Strut,
Strut Component, and Spring Replacement (See:
Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front
Suspension Strut/Strut, Strut Component, and Spring Replacement) .
8. Use your hands to lift the rear bumper approximately 38 mm (1.59 in). 9. Remove your hands
and allow the vehicle to lower.
10. Use your hands to jounce the rear of the vehicle downward approximately 38 mm (1.59 in). 11.
The dimension (R) for the left and right side of the vehicle is measured from the bottom lip of the
wheel opening to the ground measured at the
center line of the rear wheel.
12. Compare the measurement to the specification table. Refer to Trim Height Specifications (See:
Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications) .
13. If the measurement is outside of the specified range, replace the rear springs. Refer to Strut,
Strut Component, and Spring Replacement (See:
Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Rear
Suspension Strut/Strut, Strut Component, and Spring Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Wheel Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering and Suspension/Steering/Specifications) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height
Specifications) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2892
Alignment: Service and Repair Front Camber Adjustment
Front Camber Adjustment
Removal Procedure
1. Raise the vehicle and provide suitable support. Refer to Lifting and Jacking the Vehicle . 2.
Remove the tire and wheel assemblies from the front and the rear axles. Refer to Tire and Wheel
Removal and Installation (See: Wheels and
Tires/Service and Repair) .
3. Remove the strut from the vehicle. Refer to Strut, Strut Component, and Spring Replacement
(See: Steering and
Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension
Strut/Strut, Strut Component, and Spring Replacement) .
4. Place the strut in a vise and file the hole lateral - oblong. Compare the appearance of the holes
before filing (2) with after filing (3). 5. File the lower strut-to-knuckle attaching hole for a front
camber adjustment .
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install the strut to the vehicle. Refer to Strut, Strut Component, and Spring Replacement (See:
Steering and Suspension/Suspension/Suspension
Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut, Strut Component, and
Spring Replacement) .
Tighten the strut-to-knuckle nuts as far as to allow movement of the knuckle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2893
2. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) . 3. Adjust the camber (1).
Tighten the strut-to-knuckle nuts to 130 N.m (96 lb ft).
4. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2894
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
1. Remove the small seal clamp from the inner tie rod boot. 2. Position the steering wheel in the
straight ahead position.
3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe
angle. Refer to Wheel Alignment Specifications (
See: Specifications) .
4. Confirm the number of threads showing on each tie rod end is nearly equal.
Notice: Refer to Fastener Notice .
5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2).
Tighten the hex nuts at the tie rod ends to 70 N.m (52 lb ft).
Important: Ensure the seals do not twist.
6. Install the seal clamps.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2895
Alignment: Service and Repair Rear Toe Adjustment
Rear Toe Adjustment
1. Loosen the jam nuts at the rear wheel spindle rod - rear.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2896
2. Turn the adjusting nut to change the toe angle. 3. Adjust the toe to the proper setting. Refer to
Wheel Alignment Specifications (See: Specifications) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2897
Notice: Refer to Fastener Notice .
4. Tighten the jam nuts on the rear wheel spindle rod - rear.
Tighten the rear wheel spindle rod end jam nuts to 70 N.m (52 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)..................................................................................................
..............................................345-414 kPa (50-60 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information > Page 2904
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2907
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2908
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the fuel pump relay when the ignition switch is turned ON. The control
module will disable the fuel pump relay within 2 seconds unless the control module detects ignition
reference pulses. The control module continues to enable the fuel pump relay as long as ignition
reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if
ignition reference pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
*
Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Component
Tests and General Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa
(50-60 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2909
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel
rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF
with a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the fuel pump module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Powertrain Management/Computers and Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine
Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Assembly Replacement
* Fuel Injector Replacement
* Fuel Tank Fuel Pump Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Not supplied by manufacturer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Disconnect the positive crankcase ventilation (PCV) tube from the air inlet duct.
2. Loosen the air inlet duct clamp at the throttle body. 3. Remove the air inlet duct from the throttle
body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2917
4. Loosen the air inlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5.
Remove the air inlet duct from the MAF/IAT sensor.
Installation Procedure
1. Install the air inlet duct from the MAF/IAT sensor.
Notice: Refer to Fastener Notice.
2. Tighten the air inlet duct clamp at the MAF/IAT sensor.
Tighten the clamp to 3 N.m (27 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2918
3. Install the air inlet duct to the throttle body. 4. Tighten the air inlet duct clamp at the throttle body.
Tighten the clamp to 3 N.m (27 lb in).
5. Connect the PCV tube to the air inlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. 2. Release the spring clamps on top of the air cleaner
housing. 3. Remove the air cleaner housing cover. 4. Remove the air filter element.
Installation Procedure
1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Engage the spring
clamps on top of the air cleaner housing. 4. Install the air cleaner outlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2927
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2928
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2929
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
...........................................................1-8-7-2-6-5-4-3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
...........................................................397-1,337 ohms
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 2936
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
following conditions:
1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 2937
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the spark plug.
2. Remove the spark plug wire from the ignition coil (724).
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil (724). 2. Install the spark plug wire to the spark plug.
3. Inspect the spark plug wire for proper installation:
1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.......................................................1.02 mm - 0.040 in Spark Plug Torque..........................................
................................................................................................................................................15 N.m 11 lb ft
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2941
Spark Plug: Application and ID
Spark Plug
Type..........................................................................................................................................GM
P/N 12571164 (AC Spark Plug P/N 41-985)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2942
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - colder plug
- Pre-ignition causing spark plug and/or engine damage - hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2943
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively-wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over-torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes reduce or eliminates the gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2944
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot
engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug
thread damage or cylinder head damage.
1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using
compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2945
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed.
Spark plug gap: 1.016 mm (0.040 in).
3. Hand start the spark plug in the corresponding cylinder.
Notice: Refer to Fastener Notice.
4. Tighten the spark plug.
Tighten the plug to 15 N.m (11 lb ft).
5. Install the spark plug wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa (100 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2949
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
^ Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in
the 12 o'clock position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 2957
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 2958
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
2959
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
2960
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the pulleys. The drive belts are made of different
types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or
3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility
that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent
should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the
back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not
be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is
to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the
pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or
3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct
diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive
belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2963
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2964
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2965
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell
off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a
misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2966
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2967
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the A/C system over charged, the power steering
system restricted or the incorrect fluid, or an extra load on the generator. To help identify an
intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2968
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2969
Drive Belt: Service and Repair
Drive Belt Replacement - Accessory
Tools Required
EN-47988 Serpentine Belt Tension Unloader
Removal Procedure
1. Remove the passenger side diagonal brace, if more clearance is required. Refer to Front Fender
Upper Diagonal Brace Replacement . 2. Reposition the underhood bussed electrical center
(UBEC), if more clearance is required. 3. Install the EN-47988 , to the drive belt tensioner. 4.
Rotate the EN-47988 clockwise in order to relieve the tension on the belt tensioner.
5. Remove the drive belt (1) from over the power steering pump pulley.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2970
6. Slowly release the EN-47988 . 7. Remove the EN-47988 from the belt tensioner. 8. Remove the
drive belt (1) from around all the other pulleys. 9. Clean and inspect the belt surfaces of all the
pulleys.
Installation Procedure
1. Install and route the drive belt around all the pulleys except for the power steering pump pulley.
2. Ensure that when installing the EN-47988 (1), to the belt tensioner that the EN-47988 is NOT
installed above the drive belt (2).
3. Ensure that when installing the EN-47988 (1), to the belt tensioner that the EN-47988 is installed
below the drive belt (2). 4. Rotate the EN-47988 clockwise in order to relieve the tension on the belt
tensioner. 5. Ensure that the drive belt is still properly routed around all the other pulleys, then
install the drive belt over the power steering pump pulley. 6. Slowly release the EN-47988 . 7.
Remove the EN-47988 from the belt tensioner. 8. Inspect the drive belt for proper installation and
alignment. 9. Position the UBEC, if required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2971
10. Install the passenger side diagonal brace, if required. Refer to Front Fender Upper Diagonal
Brace Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Disconnect the positive crankcase ventilation (PCV) tube from the air inlet duct.
2. Loosen the air inlet duct clamp at the throttle body. 3. Remove the air inlet duct from the throttle
body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair > Page 2977
4. Loosen the air inlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5.
Remove the air inlet duct from the MAF/IAT sensor.
Installation Procedure
1. Install the air inlet duct from the MAF/IAT sensor.
Notice: Refer to Fastener Notice.
2. Tighten the air inlet duct clamp at the MAF/IAT sensor.
Tighten the clamp to 3 N.m (27 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair > Page 2978
3. Install the air inlet duct to the throttle body. 4. Tighten the air inlet duct clamp at the throttle body.
Tighten the clamp to 3 N.m (27 lb in).
5. Connect the PCV tube to the air inlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. 2. Release the spring clamps on top of the air cleaner
housing. 3. Remove the air cleaner housing cover. 4. Remove the air filter element.
Installation Procedure
1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Engage the spring
clamps on top of the air cleaner housing. 4. Install the air cleaner outlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
Passenger Compartment Air Filter Replacement
Removal Procedure
1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper
reach the desired position. 2. Open the hood. 3. Position aside the rear hood seal halfway to the
center. Refer to Hood Rear Seal Replacement. 4. Remove the washer hose from the right air inlet
grill panel and position aside.
5. Remove the 2 push pin retainers from the right air inlet grill panel.
Important: Do not remove the third push pin retainer from the right air inlet grill panel.
6. Position the left side of the right air inlet grill panel on to the windshield. 7. Remove the water
deflector cover.
8. Remove the passenger compartment air filter.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Page 2985
1. Install the passenger compartment air filter. 2. Install the water deflector cover. Ensure the three
tabs of the water deflector engage the rear cowl edge.
3. Install the air inlet grill panel into position. 4. Install the push pin retainers to the air inlet grill
panel. 5. Position the washer hose in to the right air inlet grill panel clips. 6. Install the rear hood
seal. 8. Return the windshield wipers to the PARK position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Automatic Transmission Fluid Filter and Seal Replacement
Removal Procedure
1. Remove the oil pan (24) and the gasket (25). Refer to Oil Pan Replacement (See: Transmission
and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and Repair) .
2. Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement
is necessary. 3. Inspect the oil pan and the filter for the following foreign material:
* metal particles
* clutch facing material
* rubber particles
* engine coolant
4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of
the contamination.
Installation Procedure
1. If removed, install a new seal (101).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 2989
2. Install the filter (100). 3. Install the gasket (25) and the oil pan (24). Refer to Oil Pan
Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2995
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2996
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2997
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3006
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At
Start Up
Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At
Start Up > Page 3012
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter
Application Importance
Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter
Application Importance
Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 3022
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 3023
Notice: Refer to Fastener Notice .
Important: Prior to installing a NEW oil filter, ensure that the old oil filter gasket has been removed
from the engine block. If not, remove the old gasket.
1. Install a NEW engine oil filter (437).
Tighten the filter to 30 N.m (22 lb ft).
2. Install the oil pan drain plug (430) and O-ring (429).
Tighten the drain plug to 25 N.m (18 lb ft).
3. Lower the vehicle. 4. Fill the engine with the appropriate amount and type of NEW engine oil.
Refer to Approximate Fluid Capacities and Fluid and Lubricant
Recommendations .
5. Check the oil level. 6. Install the oil fill cap. 7. Close the hood. 8. Reset the engine oil life monitor,
if necessary. Refer to GM Oil Life System Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair
Refrigerant Filter: Service and Repair
Air Conditioning (AC) Refrigerant Filter Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air
cleaner assembly. 3. Remove the A/C line coupling from the evaporator tube to condenser tube.
4. Disconnect the evaporator tube from the condenser. 5. Remove and discard the O-ring seals. 6.
Remove the refrigerant filter from the evaporator tube.
Installation Procedure
1. Replace the O-ring seals on the evaporator tube.
2. Install a new refrigerant filter to the evaporator tube. 3. Connect the evaporator tube to the
condenser. 4. Install the A/C line coupling to the evaporator tube and condenser tube. 5. Install the
air cleaner assembly. 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery
and Recharging. 7. Leak test the fittings of the component using J 39400-A.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
Coolant Line/Hose: Service and Repair
Engine Coolant Air Bleed Hose Replacement (LS4) (5.3L)
Removal Procedure
1. Drain a small amount of coolant from the radiator. Refer to Cooling System Draining and Filling
(9C1, 9C3 Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LZE, LZ4, LZG,
9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Reposition the coolant air bleed hose clamp (322) at the coolant air bleed pipe (307). 3.
Reposition the coolant air bleed hose clamp (322) at the water manifold. 4. Remove the coolant air
bleed hose from the water manifold. 5. Remove the coolant air bleed hose from the coolant air
bleed pipe. 6. Remove the clamps from the coolant air bleed hose, if necessary.
Installation Procedure
1. Install the clamps onto the coolant air bleed hose, if necessary. 2. Install the coolant air bleed
hose onto the coolant air bleed pipe. 3. Install the coolant air bleed hose onto the water manifold. 4.
Position the coolant air bleed hose clamp (322) at the water manifold. 5. Position the coolant air
bleed hose clamp (322) at the coolant air bleed pipe (307). 6. Refill the coolant system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Engine, Cooling and
Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3,
GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill) , as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4)
Heater Hose: Service and Repair Heater Inlet Hose Replacement (LS4)
Heater Inlet Hose Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Use J 38185 to reposition the heater inlet hose clamp at the heater pipe.
Important: Cap or plug the cooling components to prevent system contamination.
3. Remove the heater inlet hose (1) from the heater pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3035
4. Use J 38185 to reposition the heater inlet hose clamp at the heater core. 5. Remove the heater
inlet hose (1) from the heater core.
Installation Procedure
1. Connect heater inlet hose (1) to the heater core. 2. Use J 38185 to reposition the heater inlet
hose to the heater core clamp.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3036
3. Install the heater inlet hose (1) to the heater pipe. 4. Use J 38185 to reposition the heater inlet
hose to the heater pipe clamp. 5. Fill the cooling system. Refer to Cooling System Draining and
Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3037
Heater Hose: Service and Repair Heater Outlet Hose Replacement (LS4)
Heater Outlet Hose Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Use J 38185 to reposition the heater outlet hose clamp to the heater pipe. 3. Remove the heater
outlet hose (2) from the heater pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3038
4. Use J 38185 to reposition the heater outlet hose to the heater core clamp. 5. Remove the heater
outlet hose (2) from the heater core.
Installation Procedure
1. Connect heater outlet hose (2) to the heater core. 2. Use J 38185 to reposition the heater outlet
hose to heater core clamp.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3039
3. Install the heater outlet hose (2) to the heater pipe. 4. Use J 38185 to reposition the heater outlet
hose to the heater pipe clamp. 5. Fill the cooling system. Refer to Cooling System Draining and
Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3040
Heater Hose: Service and Repair Heater Pipes Replacement (LS4)
Heater Pipes Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Remove the air cleaner assembly. 2. Drain the cooling system. Refer to Cooling System
Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
3. Release and reposition the heater inlet and outlet hose clamps using the J 38185.
Important: Cap or plug the cooling components to prevent system contamination.
4. Remove the heater hoses from heater pipes.
Notice: Do not apply excessive force on the heater core pipes during hose removal. Applying
excessive force on the heater core pipes may damage the heater core pipes.
5. Remove the heater pipe assembly retaining bolts from the rear the of engine.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3041
6. Remove the heater pipe assembly retaining bolt from the front of the engine. 7. Release and
reposition the heater pipe hose clamps at the engine using the J 38185. 8. Remove the heater pipe
hoses from the engine. 9. Remove the heater pipe assembly from the vehicle.
Installation Procedure
1. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly
at the engine and heater hoses. 2. Install the heater pipe assembly into position in the vehicle. 3.
Install the heater pipe hoses to the engine. 4. Reposition and release the heater pipe hose clamps
at the engine using the J 38185. 5. Loosely install the heater pipe assembly retaining bolt to the
front of the engine.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LS4) > Page 3042
Notice: Refer to Fastener Notice.
6. Install the heater pipe assembly retaining bolts to the rear of the engine.
Tighten all the heater pipe assembly bolts to 16 N.m (12 lb ft).
7. Connect heater hoses to the heater pipe assembly. 8. Install the heater hose clamps into
position using the J 38185. 9. Install the air cleaner assembly.
10. Fill the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement
Hose/Line HVAC: Service and Repair Air Conditioning Line/Tube Connector
Removal/Replacement
Air Conditioning Line/Tube Connector Removal/Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Locate the A/C coupling assembly's locking tab access slots (1).
Important: When separating the A/C coupling assembly, apply light pressure between the two
halves of the coupling to prevent the
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement > Page 3047
locking tabs from reengaging.
3. Carefully insert a small flat bladed screwdriver into the first locking tab access slot and gently lift
the locking tab to release the lock.
4. Carefully insert a small flat bladed screwdriver into the second locking tab access slot and gently
lift the locking tab to release the lock.
5. Open and remove the A/C coupling assembly from the A/C refrigerant component.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement > Page 3048
Important: Inspect the A/C coupling assembly locking tabs for damage or wear. Replace the A/C
coupler assembly if any conditions exist.
1. Install the A/C coupling assembly to the A/C refrigerant component.
Important: Ensure that the A/C coupling assembly is latched securely to the A/C refrigerant
component.
2. Close the A/C coupling assembly. 3. Evacuate and recharge the A/C system. Refer to
Refrigerant Recovery and Recharging. 4. Leak test the fittings of the component using J 39400-A.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement > Page 3049
Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement
Compressor Hose Assembly Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement > Page 3050
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Air Conditioning Line/Tube Connector Removal/Replacement > Page 3051
Hose/Line HVAC: Service and Repair Suction Screen Replacement
Suction Screen Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Notice
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement
(3.5L and 3.9L)
Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3057
Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement
(LS4)
Power Steering Cooler Pipe/Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3058
Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Inlet Hose
Replacement (LS4)
Power Steering Fluid Reservoir Inlet Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3059
Power Steering Line/Hose: Service and Repair Power Steering Pressure Pipe/Hose Replacement
(LS4)
Power Steering Pressure Pipe/Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3060
Power Steering Line/Hose: Service and Repair
Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Power Steering Cooler Pipe/Hose Replacement (LS4)
Power Steering Cooler Pipe/Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3061
Power Steering Fluid Reservoir Inlet Hose Replacement (LS4)
Power Steering Fluid Reservoir Inlet Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3062
Power Steering Pressure Pipe/Hose Replacement (LS4)
Power Steering Pressure Pipe/Hose Replacement (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3063
Power Steering Pressure Pipe/Hose Replacement (LZ4/LZE/LZ9)
Power Steering Pressure Pipe/Hose Replacement (LZ4/LZE/LZ9)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3064
Power Steering Return Hose Replacement (LZ4/LZE/LZ9)
Power Steering Return Hose Replacement (LZ4/LZE/LZ9)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L) > Page 3065
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (RPO LS4) (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 3070
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (RPO LS4) (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM
Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Bulletin No.: 05-06-02-002B
Date: January 18, 2008
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Number 05-06-02-002A (Section 06 - Engine/Propulsion System).
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Cooling System Including Reservoir
................................................................................................................................................ 13.3
quarts (12.6 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 3081
Coolant: Fluid Type Specifications
ENGINE COOLANT
The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is
designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs
first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will:
^ Give freezing protection down to -34°F (-37°C).
^ Give boiling protection up to 265°F (129°C).
^ Protect against rust and corrosion.
^ Help keep the proper engine temperature.
^ Let the warning lights and gages work as they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE
Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't
damage aluminum parts. If you use this coolant mixture, you don't need to add anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - DEXRON(R)-VI Fluid Information
Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information
INFORMATION
Bulletin No.: 04-07-30-037E
Date: April 07, 2011
Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF)
Models:
2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008
HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION
2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo,
Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except
2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only
Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT
(MJ7/MJ8) Transmission Only Except 2008 Saturn Astra
Attention:
DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs
for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids.
Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin
Number 04-07-30-037D (Section 07 - Transmission/Transaxle).
MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING
The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle
that previously required DEXRON(R)-III for a manual transmission or transfer case should now use
P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual
transmissions and transfer cases require a different fluid. Appropriate references should be
checked when servicing any of these components.
Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid.
Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations.
Some of our customers and/or General Motors dealerships/Saturn Retailers may have some
concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and
transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for
General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the
J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with
DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as
noted above).
DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic
transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair
or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use
in automatic transmissions/transaxles.
DEXRON(R)-VI ATF
General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle
production.
Current and prior automatic transmission models that had used DEXRON(R)-III must now only use
DEXRON(R)-VI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - DEXRON(R)-VI Fluid Information > Page 3086
All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with
DEXRON(R)-VI fluid.
DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas:
* These ATF change intervals remain the same as DEXRON(R)-III for the time being.
2006-2008 Transmission Fill and Cooler Flushing
Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the
machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI.
Parts Information
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - DEXRON(R)-VI Fluid Information > Page 3087
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - DEXRON(R)-VI Fluid Information > Page 3088
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Bottom Pan Removal (2WD) ...............................................................................................................
....................................................... 7.0L (7.4 Quarts) Complete Overhaul (2WD) ..............................
......................................................................................................................................... 9.5L (10.0
Quarts) Dry (2WD) ...............................................................................................................................
.............................................................. 12.7L (13.4 Quarts)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 3091
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID
DEXRON-VI Automatic Transmission Fluid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 3092
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3101
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications
Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications > Page 3107
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications > Page 3108
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
> Page 3113
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications
Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications > Page 3119
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil
Specifications > Page 3120
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil with Filter ............................................................................................................................
............................................... 6.0 quarts (5.7 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 3123
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE Look for two things:
1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M.
2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3124
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 3125
Notice: Refer to Fastener Notice .
Important: Prior to installing a NEW oil filter, ensure that the old oil filter gasket has been removed
from the engine block. If not, remove the old gasket.
1. Install a NEW engine oil filter (437).
Tighten the filter to 30 N.m (22 lb ft).
2. Install the oil pan drain plug (430) and O-ring (429).
Tighten the drain plug to 25 N.m (18 lb ft).
3. Lower the vehicle. 4. Fill the engine with the appropriate amount and type of NEW engine oil.
Refer to Approximate Fluid Capacities and Fluid and Lubricant
Recommendations .
5. Check the oil level. 6. Install the oil fill cap. 7. Close the hood. 8. Reset the engine oil life monitor,
if necessary. Refer to GM Oil Life System Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING SYSTEM
GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Page 3129
Power Steering Fluid: Service Precautions
Using Proper Power Steering Fluid Notice
Notice: When adding fluid or making a complete fluid change, always use the proper power
steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins
> A/C - Refrigerant Recovery/Recycling/Equipment
Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment
Bulletin No.: 08-01-38-001
Date: January 25, 2008
INFORMATION
Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and
Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Attention:
This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C)
Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive
Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be
manufactured in its current state after December 2007 and will be superseded by GE-48800.
The new J2788 standard does not require that GM Dealers replace their ACR2000 units.
ACR2000's currently in use are very capable of servicing today's refrigerant systems when used
correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined
in GM Bulletin 07-01-38-004.
Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800)
will be released as a required replacement for the previously essential ACR2000 (J-43600). This
equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System
Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE)
refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships.
In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination
when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil.
The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush
Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50,
with installation instructions, as a component of the Hybrid essential tool package. Dealerships that
do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore.
Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure.
The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a
Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil.
This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.
Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C
compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It
may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost
Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be
voided.
Warranty Submission Requirements
The Electronically Generated Repair Data (snapshot summary) and printer functions have been
eliminated from the GE-48800. The VGA display and temperature probes were eliminated to
reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge
Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are
submitted for warranty reimbursement. The charge summary data from before and after system
repairs will continue to required, but documented on the repair order only. Both high and low
pressures and the recovery and charge amounts should be noted during the repair and entered on
the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should
continue to be attached to the shops copy of the repair order.
The labor codes that are affected by this requirement are D3000 through D4500.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 3136
Refrigerant: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 3137
Refrigerant: Service and Repair
Refrigerant Recovery and Recharging
Tools Required
* J 43600 ACR 2000 Air Conditioning Service Center
* J 45037 A/C Oil Injector
Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove
R-134a from the A/C system, use service equipment that is certified to meet the requirements of
SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the
work area before continuing service. Additional health and safety information may be obtained from
the refrigerant and lubricant manufacturers.
Caution: For personal protection, goggles and gloves should be worn and a clean cloth wrapped
around fittings, valves, and connections when doing work that includes opening the refrigerant
system. If R-134a comes in contact with any part of the body severe frostbite and personal injury
can result. The exposed area should be flushed immediately with cold water and prompt medical
help should be obtained.
Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.
Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through
the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure
is likely to occur. Refer to the manufacturer instructions included with the service equipment before
servicing.
The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers,
recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit
has a display screen that contains the function controls and displays prompts that will lead the
technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered
into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this
vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C
refrigerant.
The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to
recovery and will notify the technician if there are foreign gases present in the A/C system. If
foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.
The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.
Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the
A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the
correct amount.
A/C Refrigerant System Oil Charge Replenishing
If oil was removed from the A/C system during the recovery process or due to component
replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037.
For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System
Capacities.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications
Refrigerant Oil: Specifications
PAG Oil GM P/N 12378526 for United States
PAG Oil GM P/N 88900060 for Canada
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important:
* Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
* The automated bleed procedure must be performed when a new brake pressure modulator valve
(BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake
fluid.
* The automated bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out away from the brake modulator assembly, which is then forced out at the
brake corners by the pressure bleeder.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction
Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) . Repair or replace components as needed.
4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) .
6. Inspect the battery state of charge. Refer to Battery Inspection/Test . 7. Install a scan tool. 8.
Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps:
1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select
Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed
10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Important: *
Apply the brake pedal when instructed, using moderate effort.
* Ensure the pedal remains applied until instructed to release by the scan tool.
* Do not exceed the time period allowed by the scan tool for having the bleeder valves open.
*
The bleed sequence for each corner is as follows:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3145
- Left front
- Right front
Right rear
- Left rear
11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated
bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble
Code (DTC) List - Vehicle to
diagnose the DTC.
13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect
for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15.
Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal
and Installation . 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder
Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) .
19. Road test the vehicle while confirming the brake pedal remains high and firm.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3146
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
Important: If you have performed a brake master cylinder bench bleeding, disconnected the brake
pipes from the master cylinder, replaced the ABS pressure modulator valve, or disconnected the
jumper lines from the master cylinder to the ABS pressure valve, you MUST use the pressure
bleeding procedure to remove all the air from the system. Refer to Hydraulic Brake System
Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) (See: ) .
3. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian
P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains
at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
4. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 5.
Install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the
bleeder valve, then have the assistant slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air
has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left front hydraulic circuit, install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
18. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
19. Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
Important: If it is determined that air was induced into the system upstream of the ABS modulator
prior to servicing, the Antilock Brake System Automated Bleed Procedure (See: ) must be
performed.
20. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still
feels spongy after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
21. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3147
22. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 35589-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, replaced the ABS
pressure modulator valve, or disconnected the
brake lines between master cylinder and ABS on this vehicle, you must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11(R) GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
If removal of the reservoir cap is necessary, clean the outside of the reservoir on and around the
cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port, and rotate the line at the master cylinder at
least 30 degrees, so that the line will be
positioned BELOW the MAX fill line on the brake master cylinder reservoir. Tighten the line nut
securely.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7.
Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds,
then repeat steps 3.5-3.7 until all air is purged from the same port of the master cylinder. 9. With
the front brake pipe installed securely to the master cylinder - after all air has been purged from the
front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.5-3.7,
ensuring that the line is rotated below the master cylinder MAX fill line.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened, and that they remain in their new rotated positions below the MAX fill line of the brake
fluid reservoir.
4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J
29532 , or equivalent. Add Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to
approximately the half-full point.
7. Connect the J 29532 , or equivalent, to the J 35589-A . 8. Charge the J 29532 , or equivalent, air
tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow
pressurized brake fluid to enter the brake system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R) GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
14. Repeat steps 11-13 for the LEFT FRONT wheel hydraulic circuit bleeder valve. 15. Loosen the
bleeder valve to purge air from the wheel hydraulic circuit. It is important that both bleeder valves
be open at the same time. Allow
fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve.
16. With the right rear and left front wheel hydraulic circuit bleeder valve tightened securely - after
all air has been purged from the right rear and left
front hydraulic circuit - install a proper box-end wrench onto the LEFT REAR and RIGHT FRONT
wheel hydraulic circuit bleeder valve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3148
17. Install a transparent hose over the end of the bleeder valve, then repeat step 15. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Loosen the rear master cylinder jumper line nut slightly (just enough to rotate the line), and
rotate the rear master cylinder hydraulic pipe back to
the original position, and tighten the line nut.
20. Reposition the front master cylinder jumper line to the original position in a similar manner to
step 19. 21. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or
equivalent, from the J 35589-A . 22. Remove the J 35589-A from the brake master cylinder
reservoir. 23. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme
11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
24. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 25. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection) .
2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure
(See: ) .
26. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
27. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3149
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Overhaul (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Overhaul) or Master Cylinder Replacement (See: Brakes and Traction
Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master
cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using
non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary.
Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction Control/Hydraulic
System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder
Reservoir Replacement) . Replace the brake master cylinder reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 3150
* Front Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul) or Front Brake Caliper
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul) or Rear Brake Caliper
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canada P/N 992667) or
equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and
Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Enabling Procedure - Air Bag Fuse
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and
Repair > Page 3154
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams
Circuit Breaker: Diagrams
Component Connector End Views
Circuit Breaker 1 (SEO 9C1/9C3)
Circuit Breaker 2 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Diagrams > Page 3159
Circuit Breaker 3 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer Inoperative/Poor
Performance
Fuse: Customer Interest Wipers/Washers - Washer Inoperative/Poor Performance
Bulletin No.: 07-08-43-004C
Date: November 19, 2007
TECHNICAL
Subject: EI07089 - Windshield Washer Inoperative, Poor Performance (Replace WSW Fuse)
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Supercede:
This bulletin is being revised to include 2008 Impala. Please discard Corporate Bulletin Number
07-08-43-004B (Section 08 - Body and Accessories).
Condition
Some customer's may comment that the windshield washer pump operation is intermittent.
Correction
DO NOT REPLACE THE WINDSHIELD WASHER PUMP.
Engineering has determined that windshield washer pump intermittent operation or poor
performance conditions may be corrected by replacing the current 10 amp WSW fuse with a 15
amp fuse. The WSW (windshield washer) fuse is located in the UBEC (underhood bussed electrical
center).
Be sure to update the UBEC fuse label to indicate the use of a 15 amp fuse for the Windshield
Washer (WSW).
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer Inoperative/Poor
Performance > Page 3168
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer
Inoperative/Poor Performance
Fuse: All Technical Service Bulletins Wipers/Washers - Washer Inoperative/Poor Performance
Bulletin No.: 07-08-43-004C
Date: November 19, 2007
TECHNICAL
Subject: EI07089 - Windshield Washer Inoperative, Poor Performance (Replace WSW Fuse)
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Supercede:
This bulletin is being revised to include 2008 Impala. Please discard Corporate Bulletin Number
07-08-43-004B (Section 08 - Body and Accessories).
Condition
Some customer's may comment that the windshield washer pump operation is intermittent.
Correction
DO NOT REPLACE THE WINDSHIELD WASHER PUMP.
Engineering has determined that windshield washer pump intermittent operation or poor
performance conditions may be corrected by replacing the current 10 amp WSW fuse with a 15
amp fuse. The WSW (windshield washer) fuse is located in the UBEC (underhood bussed electrical
center).
Be sure to update the UBEC fuse label to indicate the use of a 15 amp fuse for the Windshield
Washer (WSW).
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer
Inoperative/Poor Performance > Page 3174
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse
Warning
Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning
Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block
Fuse: Locations Instrument Panel Fuse Block
INSTRUMENT PANEL FUSE BLOCK
The fuse block is located on the passenger side of the vehicle in the carpet molding. Remove the
fuse block door to access the fuses.
FUSES .................................................................................................................................................
...................................................................... USAGE
PWR/SEAT ..........................................................................................................................................
.......................................................... Power Seats PWR/WNDW .......................................................
..................................................................................................................................... Power Window
RAP .....................................................................................................................................................
.................................... Retained Accessory Power HTD/SEAT ..........................................................
.......................................................................................................................................... Heated
Seats AUX ...........................................................................................................................................
............................................................ Auxiliary Outlets AMP .............................................................
......................................................................................................................................................
Amplifier S/ROOF ................................................................................................................................
................................................................................ Sunroof XM .........................................................
...........................................................................................................................................................
XM Radio CNSTR ...............................................................................................................................
.................................................................................. Canister DR/LCK ..............................................
............................................................................................................................................................
Door Locks
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3186
PWR/MIR .............................................................................................................................................
...................................................... Power Mirrors AIRBAG .................................................................
............................................................................................................................................... Airbags
TRUNK ................................................................................................................................................
.................................................................... Trunk TRUNK .................................................................
......................................................................................................................................... Trunk Relay
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3187
Fuse: Locations I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3188
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3189
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3190
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Instrument Panel Fuse Block > Page 3191
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 3194
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagram Information and Instructions > Page 3195
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Diagram Information and Instructions > Page 3196
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Diagram Information and Instructions > Page 3197
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Diagram Information and Instructions > Page 3198
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Diagram Information and Instructions > Page 3199
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Diagram Information and Instructions > Page 3200
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Diagram Information and Instructions > Page 3201
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Diagram Information and Instructions > Page 3202
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Diagram Information and Instructions > Page 3203
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Diagram Information and Instructions > Page 3204
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Diagram Information and Instructions > Page 3205
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Diagram Information and Instructions > Page 3206
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Diagram Information and Instructions > Page 3207
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Diagram Information and Instructions > Page 3208
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Diagram Information and Instructions > Page 3209
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagram Information and Instructions > Page 3210
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagram Information and Instructions > Page 3211
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Diagram Information and Instructions > Page 3212
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Diagram Information and Instructions > Page 3213
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Diagram Information and Instructions > Page 3214
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Diagram Information and Instructions > Page 3215
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Diagram Information and Instructions > Page 3216
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Diagram Information and Instructions > Page 3217
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Diagram Information and Instructions > Page 3218
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Diagram Information and Instructions > Page 3219
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Diagram Information and Instructions > Page 3220
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 3221
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 3222
Fuse: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 3223
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 3224
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and ID > Underhood Fuse Block
Fuse: Application and ID Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuse: Application and ID I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P - Label
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Locations > Instrument Panel/Center Console Component Views
Fuse Block: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel Harness - Rear of the Instrument Panel Carrier
1 - J282 2 - J203 3 - J239 4 - J250 5 - J218 6 - Instrument Panel Carrier 7 - J259 8 - J269 9 - Fuse
Block - Auxiliary
Right Front of the Passenger Compartment
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1 - Dash Panel 2 - Fuse Block - Instrument Panel 3 - X303 4 - G302
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Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Battery Attachments (LZE/LZ4/LZ8)
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1 - G102 2 - X105 3 - Fuse Block - Underhood Positive Battery Cable Terminal 4 - Battery 5 Battery Current Sensor
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Fuse Block: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Fuse Block: Connector Views
Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood - Top View
Fuse Block - Underhood - Bottom View
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Fuse Block - Underhood X1
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Fuse Block - Underhood X2
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Fuse Block - Underhood X3
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Fuse Block - Underhood X4
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 3472
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 3473
I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P Top View
Fuse Block - I/P X1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 3474
Fuse Block - I/P X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 3475
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
- Right Side (Impala)
Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala) > Page 3478
Fuse Block: Service and Repair Accessory Wiring Junction Block Replacement
Accessory Wiring Junction Block Replacement
Removal Procedure
1. Remove the electrical center cover (1). 2. Disconnect the positive battery cable from junction
box.
3. Remove the fasteners (1) securing the electrical center board (2). 4. Unlock the tabs on the
electrical center board. 5. Lift up on the electrical center board.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala) > Page 3479
6. Remove the fasteners (1) securing the electrical center bracket (2) to vehicle.
Installation Procedure
Notice: Refer to Fastener Notice.
1. Install fasteners (1) securing the electrical center (2) to vehicle.
Tighten the fasteners to 10 N.m (86 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala) > Page 3480
2. Install the fasteners (1) securing the electrical center board (2).
Tighten the fasteners to 7 N.m (62 lb in).
3. Connect the positive battery cable.
4. Install the electrical center cover (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3486
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3487
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3488
Customer TPMS Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3489
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3490
Frequently Asked Questions
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. See: Oil Change
Reminder Lamp/Service and Repair
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
^ If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
^ If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM.
^ If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Instrument Cluster Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
ENGINE OIL LIFE SYSTEM
WHEN TO CHANGE ENGINE OIL
Your vehicle has a computer system that lets you know when to change the engine oil and filter.
This is based on engine revolutions and engine temperature, and not on mileage. Based on driving
conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil
life system to work properly, you must reset the system every time the oil is changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. A "CHANGE ENGINE OIL SOON" message will come on. Change the oil as soon as
possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best
conditions, the oil life system might not indicate that an oil change is necessary for over a year.
However, the engine oil and filter must be changed at least once a year and at this time the system
must be reset. It is also important to check the oil regularly and keep it at the proper level.
If the system is ever reset accidentally, you must change the oil at 3,000 miles (5 000 km) since
your last oil change. Remember to reset the oil life system whenever the oil is changed.
HOW TO RESET THE ENGINE OIL LIFE SYSTEM
The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle
use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is
required. If a situation occurs where you change the oil prior to a "CHANGE ENGINE OIL SOON"
message being turned on, reset the system.
Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the
Engine Oil Life System: 1. Display the "OIL LIFE REMAINING" on the Driver Information Center
(DIC). 2. Press and hold the "SET/RESET" button on the DIC for more than five seconds. The oil
life will change to 100%.
If the "CHANGE ENGINE OIL SOON" message comes back on when you start your vehicle, the
Engine Oil Life System has not reset. Repeat the procedure.
WHAT TO DO WITH USED OIL
Used engine oil contains certain elements that can be unhealthy for your skin and could even
cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with
soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing
used engine oil. See the manufacturer's warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil
from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the
ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place
that collects used oil. If you have a problem properly disposing of used oil, ask your dealer/retailer,
a service station, or a local recycling center for help.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Technician Safety Information
Vehicle Lifting: Technician Safety Information
Vehicle Lifting Caution
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Technician Safety Information > Page 3505
Vehicle Lifting: Vehicle Damage Warnings
Vehicle Lifting and Jacking Notice
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 3506
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Automotive Lift and Floor Jack Contact Points
1 - Floor Jacking-Front Location 2 - Suspension Contact Lift-Front Location 3 - Frame Contact
Lift-Front Location 4 - Frame Contact Lift-Rear Location 5 - Suspension Contact Lift-Rear Location
6 - Floor Jacking-Rear Location
Vehicle Lifting-Frame Contact Lift
Front Lift Pads
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 3507
When lifting the vehicle with a frame-contact lift, place the front lift pads at the front pinchweld
flanges.
Rear Lift Pads
When lifting the vehicle with a frame-contact lift, place the rear lift pads at the rear pinchweld
flanges.
Vehicle Lifting-Suspension Contact Lift
When lifting the vehicle with a suspension-contact lift, place the front post lift points at the lower
control arms in the area shown (1). Lift the rear of the vehicle with the rear post lift points ONLY
under the rear wheels.
Vehicle Jacking
Under the Front Frame
When lifting the front of the vehicle with a floor jack, place the floor jack lift pad at the center of the
front frame.
Under the Center of the Rear Suspension
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 3508
Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.
Supporting the Vehicle with Jackstands
Important: Place jackstands ONLY under strong and stable vehicle structures.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM
Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3523
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3524
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3525
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3526
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3527
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 3528
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement (Snap In Style)
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Mounting and Dismounting
(See: Tires/Service and Repair/Removal and Replacement) .
Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure
monitor (TPM) and a new TORX screw during installation.
4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire
pressure valve stem (3).
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
5. Remove the tire pressure valve stem by pulling it through the rim.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 3529
Notice: Refer to Fastener Notice .
Important: *
Ensure the flat of the valve, lines up with the flats of the snap in the enclosure.
* TPM valves and TORX screws are one-time use only.
1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3).
Tighten the TORX screw to 1.3 N.m (11.5 lb in).
Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base
compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire
or rim deterioration.
2. Apply tire soap to the rubber portion of the valve stem (1).
3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the
valve hole on the rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 3530
Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer
needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire
is inflated. The technician can then program the vehicle as normal.
4. Mount the tire to the rim. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the
tire pressure sensors. Refer to Tire Pressure Sensor Learn () .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3536
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3537
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3538
Customer TPMS Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3539
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3540
Frequently Asked Questions
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor
Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor
Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3553
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3554
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3555
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3556
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3557
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > Page 3558
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement (Snap In Style)
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Mounting and Dismounting
(See: Tires/Service and Repair/Removal and Replacement) .
Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure
monitor (TPM) and a new TORX screw during installation.
4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire
pressure valve stem (3).
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
5. Remove the tire pressure valve stem by pulling it through the rim.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > Page 3559
Notice: Refer to Fastener Notice .
Important: *
Ensure the flat of the valve, lines up with the flats of the snap in the enclosure.
* TPM valves and TORX screws are one-time use only.
1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3).
Tighten the TORX screw to 1.3 N.m (11.5 lb in).
Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base
compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire
or rim deterioration.
2. Apply tire soap to the rubber portion of the valve stem (1).
3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the
valve hole on the rim.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > Page 3560
Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer
needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire
is inflated. The technician can then program the vehicle as normal.
4. Mount the tire to the rim. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the
tire pressure sensors. Refer to Tire Pressure Sensor Learn () .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3565
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3566
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3567
Customer TPMS Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3568
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3569
Frequently Asked Questions
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning
Sensor IDs
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
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Procedures > Page 3579
2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3580
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
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Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3581
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3582
1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
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Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3583
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires
> Page 3588
degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3593
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3594
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3595
Customer TPMS Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3596
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3597
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 07-03-10-008B > Aug > 09 > Tires - Slight/Mild Edge Feathering
Information
Tires: Technical Service Bulletins Tires - Slight/Mild Edge Feathering Information
INFORMATION
Bulletin No.: 07-03-10-008B
Date: August 13, 2009
Subject: Information on Slight or Mild Tire Feathering and Recommended Practices (Normal Tire
Wear Condition)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2010 HUMMER H2,
H3 2006-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 07-03-10-008A (Section 03 - Suspension).
This bulletin provides information regarding the normal tire wear condition of slight or mild tire
feathering and recommended practices.
If a vehicle comes into a dealership with a concern of slight or mild feathering-type wear on the
tires, review with the customer their past tire rotation history. Tires should be rotated every 8,000 to
13,000 km (5,000 to 8,000 mi) for applicable vehicles with tires where a tire rotation is possible or
recommended. Refer to Corporate Bulletin Number 05-03-10-015B for information on tire rotation
for vehicles with different front/rear tire/wheel sizes.
SOME TIRE FEATHERING IS A NORMAL PART OF TIRE WEAR AND THROUGH PROPER
TIRE ROTATION AND INFLATION, THIS TIRE WEAR CAN BE MINIMIZED AND TIRE LIFE
MAXIMIZED.
If the customer has not rotated the tires within the last 8,000 to 13,000 km (5,000 to 8,000 mi), a
tire rotation in the modified X-pattern is necessary to clean-up the feathering, rather than placing
the vehicle on the alignment machine.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information
Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information
INFORMATION
Bulletin No.: 00-00-90-002J
Date: January 28, 2009
Subject: Information on Proper Tire Pressure
Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X
Supercede:
This bulletin is being revised to add model years and clarify additional information. Please discard
Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information).
Important:
^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and
no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure
will be rejected.
^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on
the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI).
Recommended inflation pressure is not the pressure printed on tire sidewall.
^ Tires may be over-inflated from the assembly plant due to the mounting process.
^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure change.
^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires
with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a
low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which
specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window
of "usable" pressure values and the warning will be more sensitive to outside temperature changes
during the colder months. As with other cold temperature/tire pressure issues, there is nothing
wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and
set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard.
Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars
and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s
tire placard during PDI.
Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure.
The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct
pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The
tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear
compartment lid.
Tip
^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure increase.
^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more
than 1.6 km (1 mi).
^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for
the low external temperature by adding additional air to the tire during PDI.
^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an
exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating
temperature), the tire pressure should be reset to placard pressure at the cold temperature.
^ The TPM system will work correctly with nitrogen in tires.
^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other
commercially available sealants.
Important:
^ Do not use the tire pressure indicated on the tire itself as a guide.
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Bulletins > Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information
> Page 3606
^ Always inspect and adjust the pressure when the tires are cold.
^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire
rotation.
Improper tire inflation may result in any or all of the following conditions:
^ Premature tire wear
^ Harsh ride
^ Excessive road noise
^ Poor handling
^ Reduced fuel economy
^ Low Tire Pressure Monitor (TPM) Light ON
^ Low Tire Pressure Message on the Drivers Information Center (DIC)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3607
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3608
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3609
degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3610
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3611
2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3612
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3613
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3614
1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3615
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description
Tires: Description and Operation Tread Wear Indicators Description
Tread Wear Indicators Description
Tread Wear Indicators Description
The original equipment tires have tread wear indicators that show when you should replace the
tires.
The location of these indicators are at 60 degree intervals around the outer diameter of the tire.
The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm
(2/32 in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description > Page 3618
Tires: Description and Operation Tire Inflation Description
Tire Inflation Description
When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and
tires are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures,
or under-inflated tires, can cause the following conditions:
* Vehicle handling concerns
* Poor fuel economy
* Shortened tire life
* Tire overloading
Inspect the tire pressure when the following conditions apply:
* The vehicle has been sitting at least 3 hours.
* The vehicle has not been driven for more than 1.6 km (1 mi).
* The tires are cool.
Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications
on the tire label. Install the valve caps or the extensions on the valves. The caps or the extensions
keep out dust and water.
The kilopascal (kPa) is the metric term for pressure. The tire pressure may be printed in both
kilopascal (kPa) and psi. One psi equals 6.9 kPa.
Tires with a higher than recommended pressure can cause the following conditions:
* A hard ride
* Tire bruising
* Rapid tread wear at the center of the tire
Tires with a lower than recommended pressure can cause the following conditions:
* A tire squeal on turns
* Hard steering
* Rapid wear and uneven wear on the edge of the tread
* Tire rim bruises and tire rim rupture
* Tire cord breakage
* High tire temperatures
* Reduced vehicle handling
* High fuel consumption
* Soft riding
Unequal pressure on the same axle can cause the following conditions:
* Uneven braking
* Steering lead
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description > Page 3619
* Reduced vehicle handling
Refer to the Tire Placard for specific tire and wheel applications and tire pressures.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description > Page 3620
Tires: Description and Operation Tire Chain Usage Description
Tire Chain Usage Description
Tire Chain Usage Description
When you use tire chains, most current vehicles require the following chain types:
* SAE Class S or 1100 Series, Type PL tire chains (1)
* SAE Class U or 1200 Series, Type P tire chains (2)
* 1800 Series Lug Reinforced tire chains (3)
These chains are specially designed in order to limit the fly-off effect that occurs when the wheel
rotates.
Manufacturers of tire chains have a specific chain size for each tire size. These ensure a proper fit
when the chains are installed. Purchase the correct chains for the tires on which the chains will be
used. Do not use rubber adjusters to take up slack in chains that are loose due to incorrect size.
Always follow the chain manufacturer's installation instructions.
The use of chains may adversely affect handling. When using chains, remember the following
information:
* Ensure that the vehicle is designed for chain clearance.
* Adjust the speed to road conditions.
* Avoid sharp turns.
* Avoid locked-wheel braking in order to prevent chain damage to the vehicle.
* Install the chains as tightly as possible on the drive tires. Tighten the chains again after driving
0.4-0.8 km (0.25-0.5 mi). Do not use chains on the non-drive tires. These chains may contact and
damage the vehicle. If you use chains on the non-drive tires, ensure that there is enough
clearance.
* Do not exceed 70 km/h (45 mph). Do not exceed the chain manufacturer's speed limit, if lower.
* Drive in a restrained manner. Avoid large bumps, potholes, severe turns, and other maneuvers
that cause the tires to bounce up and down.
* Follow any other instructions from the chain manufacturer that do not disagree with the above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description > Page 3621
Tires: Description and Operation All Seasons Tires Description
All Seasons Tires Description
Most GM vehicles are equipped with steel belted all-season radial tires as standard equipment.
These tires qualify as snow tires, with a higher than average rating for snow traction than the
non-all season radial tires previously used. Other performance areas, such as wet traction, rolling
resistance, tread life, and air retention, are also improved. This is done by improvements in both
tread design and tread compounds. These tires are identified by an M + S molded in the tire side
wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification
number.
The optional handling tires used on some vehicles now also have the MS marking after the tire size
and the TPC specification number.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description > Page 3622
Tires: Description and Operation P-Metric Sized Tires Description
P-Metric Sized Tires Description
P-Metric Sized Tires Description
Replacement tires should be of the same tire performance criteria (TPC) specification number. This
will ensure the same size, the same load range, and the same construction as those originally
installed on the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures
Tires: Procedures
Tire Repair
Tire Repair
Caution:
* Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
* Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
* NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
* NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important:
* NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth.
* NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in).
* NEVER substitute an inner tube for a permissible or non-permissible repair.
* NEVER perform an outside-in tire repair (plug only, on the wheel).
* Every tire must be removed from the wheel for proper inspection and repair.
* Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
* Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep
moisture out. 3. Seal the inner liner with a repair unit to prevent air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3625
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3626
Clean the Injury Channel
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this
step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3627
Important: Do not install the repair unit in this step.
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3628
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads
excessively.
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3629
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
Consult your repair material supplier for the proper stitching tool.
Safety Cage
Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire
safety cage must be used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3630
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - Off Vehicle .
For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA)
1400 K Street, N.W., Suite 900 Washington, DC 20005-2403
Tire Rotation
Tire Rotation
Rotate the tires and wheels at frequent intervals to equalize wear. Refer to tire rotation in
Maintenance and Lubrication. In addition to scheduled rotation, rotate the tire and wheel whenever
uneven tire wear is noticed.
Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in
non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes
regular rotation especially necessary.
Refer to Tire and Wheel Removal and Installation (See: Service and Repair) for tire removal.
Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then, set
the tire pressure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3631
Tires: Removal and Replacement
Tire Mounting and Dismounting
Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons
alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could
result.
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of
improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air
to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire
changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage
may result in vibration and/or shimmy, and under severe usage lead to wheel cracking.
1. Deflate the tire completely.
Important: Rim-clamp, sometimes called-European-type tire changers are recommended.
2. Use the tire changer in order to remove the tire from the wheel. 3. Remove all residual liquid
sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire
dismounting on vehicles
equipped with TPM, replace the tire pressure sensor. Refer to Tire Pressure Indicator Sensor
Replacement (Snap In Style) (See: Sensors and Switches - Wheels and Tires/Tire Pressure
Sensor/Service and Repair) .
4. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or
corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound
can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration.
5. Apply GM P/N 12345884 (Canadian P/N 5728223) or equivalent to the tire bead and the wheel
rim. 6. Use the tire changer in order to install the tire to the wheel.
Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may
break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when
inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads,
deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause
serious personal injury.
7. Inflate the tire to the proper air pressure. 8. Ensure that the locating rings are visible on both
sides of the tire in order to verify that the tire bead is fully seated on the wheel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV)
Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3640
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3641
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3642
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels >
Page 3647
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3652
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3653
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3654
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3660
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3661
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3662
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 3667
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3672
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3673
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV)
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3678
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3679
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3680
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels > Page 3685
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON
Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3690
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3691
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3692
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust
Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3702
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3703
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3704
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 3709
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3714
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3715
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust
Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and
Operation > Replacement Wheels Description
Wheels: Description and Operation Replacement Wheels Description
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout.
* The wheel is bent.
* The wheel is cracked.
* The wheel is severely rusted.
* The wheel is severely corroded.
Important: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s)
or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or
non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor
vehicle handling and loss of vehicle control resulting in personal injury.
Notice: The use of non-GM original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and
Operation > Replacement Wheels Description > Page 3722
Wheels: Description and Operation Steel Wheel Repair Description
Steel Wheel Repair Description
Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from
striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and
uncontrolled heating from welding affects the properties of the material.
Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed
ratings are greatly reduced.
You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel
with a wheel of original equipment quality.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair
> Aluminum Wheel Porosity Repair
Wheels: Service and Repair Aluminum Wheel Porosity Repair
Aluminum Wheel Porosity Repair
1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair) . 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3.
Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the
wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to
indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Refer to Tire
Mounting and Dismounting (See: Tires/Service and Repair/Removal and Replacement) .
Important: Do not damage the exterior surface of the wheel.
7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use
general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 9. Apply
3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or
equivalent, to the leak area.
10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve
stem on the wheel. 12. Install the tire to the wheel. Refer to Tire Mounting and Dismounting (See:
Tires/Service and Repair/Removal and Replacement) . 13. Pressurize the tire to 276 kPa (40 psi).
14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Inflate the tire
to the specified pressure as stated on the tire placard. 16. Balance the tire and wheel. Refer to Tire
and Wheel Assembly Balancing - Off Vehicle . 17. Install the tire and wheel. Refer to Tire and
Wheel Removal and Installation (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair
> Aluminum Wheel Porosity Repair > Page 3725
Wheels: Service and Repair Aluminum Wheel Refinishing
Aluminum Wheel Refinishing
Finish Damage Evaluation Procedure
Important: *
If the wheels are chrome-plated, do not re-plate or refinish the wheels.
* If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize
a refinisher that meets manufacturer guidelines.
1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car
wash facilities. 2. Inspect the wheels for the following conditions:
* Corrosion
* Scrapes
* Gouges
3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for
cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim
flange is bent, discard the wheel.
Refinishing Procedure
Caution: To avoid serious personal injury when applying any two part component paint system,
follow the specific precautions provided by the paint manufacturer. Failure to follow these
precautions may cause lung irritation and allergic respiratory reaction.
1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair) . 2. Remove the balance weights from the wheel. 3. Remove
the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) . 4. Use a suitable cleaner in order to remove the following
contaminants from the wheel:
* Lubricants
* Wax
* Dirt
Important: *
Do not re-machine the wheel.
*
Do not use chemicals in order to strip the paint from the wheel.
5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a
machined aluminum finish, spin the wheel and use sand paper in order to restore the circular
machined appearance.
Important: The wheel mounting surface and the wheel nut contact surface must remain free of
paint.
7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint
manufacturer's instructions for painting the wheel. 9. Unmask the wheel.
10. Install a new valve stem.
Important: Use new coated balance weights in order to balance the wheel.
11. Install the tire to the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) . 12. Use a suitable cleaner in order to remove the following
contaminants from the wheel mounting surface:
* Corrosion
* Overspray
* Dirt
13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Tools Required
J 42129 Wheel Hub Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) .
3. Disconnect the wheel speed sensor electrical connector (2), if equipped.
4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. 5. Remove
the front wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement (See: Transmission and
Drivetrain/Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Service and Repair) .
6. Remove the brake rotor. Refer to Front Brake Rotor Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3731
7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in
order to push the wheel drive shaft out of the wheel bearing/hub.
9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub.
Important: Ensure that the wheel drive shaft outer seal/boot is not damaged.
10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for
re-installation.
Installation Procedure
1. Install the wheel bearing/hub with the splash shield as noted during removal.
Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are
removed. Failure to replace these fasteners after they become loose or are removed may cause
loss of vehicle control and personal injury.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3732
Notice: Refer to Fastener Notice .
2. Install NEW wheel bearing/hub bolts.
Tighten the NEW wheel bearing/hub bolts to 130 N.m (96 lb ft).
3. Install the brake rotor and caliper. Refer to Front Brake Rotor Replacement . 4. Install the front
wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement (See: Transmission and
Drivetrain/Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Service and Repair) .
Important: Ensure that the connector clip engages the bracket properly.
5. Install the wheel speed sensor electrical connector to the bracket, if equipped.
6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 8. Lower the
vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3733
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Removal Procedure
Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is
non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing
assembly.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the brake rotor. Refer to Rear Brake Rotor Replacement .
Rear Wheel Speed Sensors
4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove
the park brake cable from the park brake actuator. Refer to Parking Brake Rear Cable
Replacement (Z7U) . 6. Remove the mounting bolts from the rear bearing/hub.
7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park
brake actuator from the rear wheel bearing/hub. Refer to Parking Brake Actuator Replacement .
Installation Procedure
1. Install the park brake actuator to the rear wheel bearing/hub. Refer to Parking Brake Actuator
Replacement . 2. Install the wheel bearing/hub and park brake assembly to the knuckle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3734
Notice: Refer to Fastener Notice .
3. Install the wheel bearing/hub-to-knuckle bolts.
Tighten the bolts to 75 N.m (55 lb ft).
4. Install the park brake cable to the park brake actuator. Refer to Parking Brake Rear Cable
Replacement (Z7U) .
Rear Wheel Speed Sensors
5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the
brake rotor. Refer to Rear Brake Rotor Replacement . 7. Install the tires and wheels. Refer to Tire
and Wheel Removal and Installation (See: Service and Repair) . 8. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 11-03-08-001 > Apr > 11 > Steering - Growl
Type Noise Coming from Front of Vehicle
Axle Nut: All Technical Service Bulletins Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 11-03-08-001 > Apr > 11 > Steering - Growl
Type Noise Coming from Front of Vehicle > Page 3744
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > Customer Interest for Axle Nut: > 11-03-08-001 > Apr > 11 > Steering - Growl Type Noise
Coming from Front of Vehicle
Axle Nut: Customer Interest Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > Customer Interest for Axle Nut: > 11-03-08-001 > Apr > 11 > Steering - Growl Type Noise
Coming from Front of Vehicle > Page 3750
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > Page 3751
Axle Nut: Specifications
Front Wheel drive shaft nut. Tighten the nut to ...................................................................................
................................................................................................ 160 N.m (118 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Nuts Tighten in sequence shown. Tighten to ...........................................................................
..................................................................................................................... 140 Nm (100 lb ft.)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 3755
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 6627-A Tie Rod Puller
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Without disconnecting the hydraulic brake hose, remove and support the brake caliper and bracket
as an assembly. 4. Remove the brake rotor. Refer to Front Brake Rotor Replacement .
5. Rotate the bearing hub to a position where the least amount of interference between the stud
and the steering knuckle exists. 6. Using the J 6627-A , release the wheel stud (1) from the bearing
hub (2) and discard the stud.
Important: Some models may require additional clearance for stud removal.
7. If necessary, loosen the wheel bearing/hub assembly retaining bolts enough to walk the bearing
away slightly from the knuckle. Refer to Front
Wheel Bearing and Hub Replacement (See: Wheel Bearing/Service and Repair/Front Suspension)
.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3758
1. Install the NEW stud in the bearing hub. 2. Tighten the wheel bearing/hub assembly bolts, if
loosened during removal. Refer to Front Wheel Bearing and Hub Replacement (See: Wheel
Bearing/Service and Repair/Front Suspension) .
3. Add enough washers (3) in order to draw the stud into the hub (2). 4. Install the wheel nut (1)
with the flat side against the washers (3).
Important: Fully seat the wheel stud against the hub flange (2).
5. Tighten the wheel nut (1) until the head of the wheel stud is fully seated against the back of the
bearing hub flange. 6. Remove the wheel nut (1) and the washers (3). 7. Install the brake rotor, and
the brake caliper and bracket as an assembly. Refer to Front Brake Rotor Replacement . 8. Install
the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair) . 9. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3759
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 6627-A Tie Rod Puller
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the rear wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub
Replacement (See: Wheel Bearing/Service and Repair/Rear
Suspension) .
4. Separate the support from the rear hub. Refer to Park Brake Support Replacement .
5. Use the J 6627-A in order to extract the stud (1) from the hub (2).
Installation Procedure
1. Install a replacement stud in the wheel hub. 2. Add enough washers (3) in order to draw the stud
into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3).
Important: Fully seat the wheel stud against the hub flange (2).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3760
4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off
the wheel nut (1) and remove the washers (3). 6. Install the support. Refer to Park Brake Support
Replacement . 7. Install the rear wheel bearing/hub assembly. Refer to Rear Wheel Bearing and
Hub Replacement (See: Wheel Bearing/Service and Repair/Rear
Suspension) .
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 9. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions >
Technician Safety Information
Vehicle Lifting: Technician Safety Information
Vehicle Lifting Caution
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions >
Technician Safety Information > Page 3765
Vehicle Lifting: Vehicle Damage Warnings
Vehicle Lifting and Jacking Notice
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page
3766
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Automotive Lift and Floor Jack Contact Points
1 - Floor Jacking-Front Location 2 - Suspension Contact Lift-Front Location 3 - Frame Contact
Lift-Front Location 4 - Frame Contact Lift-Rear Location 5 - Suspension Contact Lift-Rear Location
6 - Floor Jacking-Rear Location
Vehicle Lifting-Frame Contact Lift
Front Lift Pads
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page
3767
When lifting the vehicle with a frame-contact lift, place the front lift pads at the front pinchweld
flanges.
Rear Lift Pads
When lifting the vehicle with a frame-contact lift, place the rear lift pads at the rear pinchweld
flanges.
Vehicle Lifting-Suspension Contact Lift
When lifting the vehicle with a suspension-contact lift, place the front post lift points at the lower
control arms in the area shown (1). Lift the rear of the vehicle with the rear post lift points ONLY
under the rear wheels.
Vehicle Jacking
Under the Front Frame
When lifting the front of the vehicle with a floor jack, place the floor jack lift pad at the center of the
front frame.
Under the Center of the Rear Suspension
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page
3768
Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.
Supporting the Vehicle with Jackstands
Important: Place jackstands ONLY under strong and stable vehicle structures.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Locations
Valve Deactivation Solenoid: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions
Valve Deactivation Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3777
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3778
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3779
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3780
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3781
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3782
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3783
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3784
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3785
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3786
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3787
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3788
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3789
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3790
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Valve Deactivation Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3816
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3880
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3884
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3888
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3895
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3897
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3899
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3900
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3901
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3903
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3904
Valve Deactivation Solenoid: Connector Views
Component Connector End Views - Continued
Valve Lifter Oil Manifold (VLOM) Assembly (LS4)
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Deactivation Solenoid > Component Information > Diagrams > Page 3905
Valve Deactivation Solenoid: Description and Operation
Cylinder Deactivation (Active Fuel Management) System Description
To provide maximum fuel economy under light load driving conditions, the engine control module
(ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1 and 7 on
the left bank, and cylinders 4 and 6 on the right bank, switching to a V4 mode. The engine will
operate on 8 cylinders, or V8 mode, during engine starting, engine idling, and medium to heavy
throttle applications.
When commanded ON, the ECM will determine what cylinder is firing, and begin deactivation on
the next closest deactivated cylinder in firing order sequence. The Gen IV engine has a firing order
of 1-8-7-2-6-5-4-3. If cylinder number 1 is on its combustion event when cylinder deactivation is
commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder
number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is
commanded ON, then the next cylinder in the firing order sequence that can be deactivated is
cylinder number 4.
Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the
selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded
locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing
contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing
contacts the camshaft lobe through a roller. During V8 mode, the locking pins are pushed outward
by spring force, locking the pin housing and outer housing together causing the lifter to function as
a normal lifter. When V4 mode is commanded ON, the locking pins are pushed inward with engine
oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter
pin housing is unlocked from the outer housing, the internal pin housing will remain stationary,
while the outer housing will move with the profile of the camshaft lobe, which results in the valve
remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each
deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter
bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking
pins used for cylinder deactivation.
Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM,
the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation
is timed so that the cylinder is on an intake event. During an intake event, the intake cam lobe is
pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The
force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them
from moving until the intake valve has closed. When the intake valve lifter reaches the base circle
of the camshaft lobe, the valve spring force is reduced, allowing the locking pins to move,
deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust
valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve
lifter to move immediately, and deactivate the exhaust valve.
By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge or exhaust
gas charge in the combustion chamber. The capture of exhaust gases in the combustion chamber
will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions
when operating in V4 mode. During the transition from V8 to V4 mode, the fuel injectors will be
turned OFF on the deactivated cylinders. The ignition system secondary voltage or spark is still
present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are
met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder
deactivation to a cycle time of 10 minutes in V4 mode, and then return to V8 mode for 1 minute.
Switching between V8 and V4 mode is accomplished in less than 250 milliseconds, making the
transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the
time for the ECM to sequence the transitions, the response time for the VLOM solenoids to
energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine
crankshaft.
The cylinder deactivation system consists of the following components:
* The VLOM assembly
* Eight special valve lifters, 2 per deactivating cylinder
* The engine oil pressure regulator valve for cylinder deactivation operation
* Gen IV cylinder deactivation engine block
* The ECM
Valve Lifter Oil Manifold (VLOM) Assembly
The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil
manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake
manifold assembly. The VLOM consists of 4 electrically operated Normally Closed Solenoids. Each
solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the
cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from a
passage on the rear of the cylinder block.
All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the
powertrain relay. The ground or control circuit for each solenoid is connected to the engine control
module (ECM).
When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid
control circuit in firing order sequence, allowing current to flow through the solenoid windings. With
the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the
VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per
cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When
vehicle-operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit
for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil
pressure in the control ports is exhausted through the body of the
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Deactivation Solenoid > Component Information > Diagrams > Page 3906
solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds
in the oil passages to purge any air trapped in the VLOM or engine block.
To control any contamination to the hydraulic circuits, a small replaceable oil screen is located in
the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire
sensor which provides oil pressure information to the ECM.
During service, use extreme care in keeping the VLOM assembly free of any contamination or
foreign material.
Engine Control Module (ECM)
The engine control module (ECM) is responsible for the management and control of all engine
functions. Each ECM comes equipped with a specific set of software/calibrations designed for that
engine and vehicle application. The ECM will determine engine operating parameters, based upon
information from a network of switches, sensors, modules and communication with other controllers
located throughout vehicle. Internal to the ECM is an integrated circuit device called a low-side
driver. The low-side driver is designed to operate internally, like an electronic switch. An individual
low-side driver controls each valve lifter oil manifold (VLOM) solenoid. When enabling conditions
for V4 mode are met, the ECM will command the low-side driver to ground each VLOM solenoid
control circuit, in firing order sequence. Internal to the low-side driver is a fault detection circuit,
which monitors the solenoid control circuit for an incorrect voltage level. If an incorrect voltage
level, such as an open, high resistance, or short to ground, is detected, the low-side driver, along
with the fault detection circuit, will communicate the condition to the central processor in the ECM.
The ECM will then command a return to V8 mode, set a corresponding DTC, and illuminate the
malfunction indicator lamp (MIL) on the instrument panel.
Cylinder Deactivation Inhibit Reasons
Listed below are the powertrain conditions that will inhibit V4 mode, while operating under light load
driving conditions:
* Engine manifold vacuum low
* Brake booster vacuum pressure low
* Accelerator pedal position rate of increase too high, electronic throttle control
* Accelerator pedal position too high, electronic throttle control
* Ignition voltage out of range
* Engine oil pressure out of range
* Engine oil temperature out of range
* Engine RPM out of range
* Transmission gear incorrect
* Transmission range incorrect
* Transmission gear shift in progress
* All cylinders activated via scan tool output control
* Minimum time in V8 mode not met
* Maximum V4 mode time exceeded
* Engine oil aeration present
* Decel fuel cutoff active
* Fuel shut-off timer active
* Minimum heater temp low, HVAC system
* Reduced engine power active, electronic throttle control
* Brake torque management active
* Axle torque limiting active
* Engine metal over temperature protection active
* Catalytic converter over temperature protection active
* Piston protection active, knock detected
* Hot coolant mode active
* Engine over speed protection active
* Fault Active or Fault Pending-cylinder deactivation is disabled for the following faults:
- Brake Booster Vacuum Sensor
- Manifold Absolute Pressure Sensor
- Engine Oil Pressure Sensor
- Engine Coolant Temperature Sensor
- Vehicle Speed Sensor
- Crankshaft Position Sensor
- Engine Misfire Detected
- Cylinder Deactivation Solenoid Driver Circuit
The scan tool output control is used to deactivate half of the engine cylinders, V4 mode, by
commanding all of the solenoids ON, or deactivate one cylinder switching to a V7 mode, by
commanding ON one solenoid. Listed below are the powertrain conditions that will inhibit V4 mode,
or V7 mode, with the engine running, while using the scan tool output control function:
* Engine speed out of range
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Deactivation Solenoid > Component Information > Diagrams > Page 3907
* Manifold absolute pressure (MAP) sensor fault
* Accelerator pedal position too high, electronic throttle control
* Piston protection active, knock detected
* Engine oil temperature out of range
* Engine oil pressure out of range
* Engine oil aeration present
* Engine metal over temperature protection active
* Accelerator pedal position rate of increase too high, electronic throttle control
* Cylinder deactivation solenoid driver circuit fault
* Engine coolant temperature sensor fault
* Catalytic converter over temperature protection active
* Brake booster vacuum pressure low
* Brake Booster Vacuum Pressure Sensor Fault
* Axle torque limiting active
* Brake torque management active
* Vehicle speed sensor fault
* Engine coolant temperature too high
* Engine not running
* Vehicle speed not zero
* Engine coolant temperature low
* Reduced Engine Power Active, electronic throttle control
* Transmission gear incorrect
* Transmission range incorrect
* Ignition voltage out of range
* Maximum V4 mode time exceeded
Listed below are the powertrain conditions that will inhibit a cylinder deactivation solenoid from
being energized, with the ignition ON and the engine OFF, while using the scan tool output control
function:
* Engine speed not zero
* Vehicle speed not zero
* Transmission not in park or neutral
* Ignition voltage out of range
For the system description covering the hydraulic/mechanical system of cylinder deactivation, refer
to Cylinder Deactivation (Active Fuel Management) System Description.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Page 3908
Valve Deactivation Solenoid: Testing and Inspection
Cylinder Deactivation (Active Fuel Management) System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit Description
To provide maximum fuel economy under light load driving conditions, the engine control module
(ECM) will command the valve lifter oil manifold (VLOM) solenoids ON, to deactivate engine
cylinders 1 and 7 on the left bank, and cylinders 4 and 6 on the right bank. The VLOM consists of 4
electrically operated normally closed solenoids, which directs pressurized engine oil to 8
deactivating valve lifters. All 4 VLOM solenoids are connected in parallel to a fused ignition circuit
supplied by the powertrain relay. The control circuit for each solenoid is connected to an individual
low side driver internal to the ECM. When enabling conditions for V4 mode are met, the ECM will
command each low side driver to turn ON, in engine firing order sequence.
Diagnostic Aids
The VLOM solenoids are assigned to the following engine cylinders:
* Solenoid #1-Cylinder #1
* Solenoid #2-Cylinder #4
* Solenoid #3-Cylinder #6
* Solenoid #4-Cylinder #7
Circuit/System Verification
1. If any DTCs are set, then repair those DTC first. Refer to Diagnostic System Check - Vehicle.
See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System Check - Vehicle
2. Start and idle the engine. 3. Allow the engine to reach normal engine operating temperature. The
engine should idle smoothly without any misfires. If the engine misfires, refer
to DTC P0300-P0308. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0300
4. Monitor the cylinder deactivation system data parameters with a scan tool. 5. Road test the
vehicle under light throttle and load conditions that will allow the ECM to command V4 mode. If all
enabling conditions are met for
cylinder deactivation, and if no internal engine hydraulic/mechanical fault conditions are present,
the ECM will continue operation in V4 mode.
^ If the vehicle passes the Circuit/System Verification test, then review the active fuel management
driving information in the Features and Controls section of the owners manual with the vehicle
operator, or instruct the vehicle operator in the proper driving techniques to obtain V4 mode.
^ If the vehicle does not pass the Circuit/System Verification test, then review the cylinder
deactivation inhibit reasons listed on the scan tool.
Circuit/System Testing
Electrical System Testing
Ignition ON and the engine OFF, command each VLOM solenoid ON and OFF using the scan tool.
Standing next to the engine compartment, you should be able to hear the solenoid energize and
de-energize with each command.
If you cannot hear each solenoid energize and de-energize, then refer to DTC P3401, P3425,
P3441, or P3449. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P3425
Mechanical System Testing
1. Connect a vacuum gage to the EVAP vacuum tube fitting on the electronic throttle body. DO
NOT use a compound pressure and vacuum gage.
The vacuum gage on a hand held vacuum pump will work fine for this test.
2. Start the engine. Allow the engine to reach normal operation temperature. 3. With a scan tool,
command each VLOM solenoid ON, one at a time. Each time a solenoid is command ON, you
should observe a fluctuating drop
of intake manifold vacuum, and a misfire on the cylinder that was deactivated.
^ If there is no fluctuating drop in engine vacuum, or the engine does not misfire, then refer to
Cylinder Deactivation (Active Fuel Management)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve
Deactivation Solenoid > Component Information > Diagrams > Page 3909
System Diagnosis.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa (100 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3913
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt - 1-Bolt Sprocket - First Pass
............................................................................................................................... 75 N.m (55 lb ft)
Camshaft Sprocket Bolt - 1-Bolt Sprocket - Final Pass
........................................................................................................................................ 50 degrees
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair
Camshaft: Service and Repair
Camshaft Replacement
Removal Procedure
1. Remove the engine. Refer to Engine Replacement (See: Service and Repair/Removal and
Replacement/Engine Replacement) . 2. Remove the crankshaft balancer. Refer to Crankshaft
Balancer Removal (See: Service and Repair/Overhaul) . 3. Remove the oil level indicator. Refer to
Oil Level Indicator and Tube Removal (See: Service and Repair/Overhaul) . 4. Remove the left and
right exhaust manifolds. Refer to Exhaust Manifold Removal - Left Side (See: Service and
Repair/Overhaul) and Exhaust
Manifold Removal - Right Side (See: Service and Repair/Overhaul) .
5. Remove the water pump. Refer to Water Pump Removal (See: Service and Repair/Overhaul) .
6. Remove the coolant pump manifold. Refer to Coolant Pump Manifold Replacement (See: Water
Pump/Service and Repair) . 7. Remove the intake manifold. Refer to Intake Manifold Removal
(See: Service and Repair/Overhaul) . 8. Remove the valve lifter oil manifold. Refer to Valve Lifter
Oil Manifold Removal (See: Service and Repair/Overhaul) . 9. Remove the coolant air bleed pipe.
Refer to Engine Coolant Air Bleed Pipe and Hole Cover Removal (See: Service and
Repair/Overhaul) .
10. Remove the left and right valve rocker arm covers. Refer to Valve Rocker Arm Cover Removal
- Left Side (See: Service and Repair/Overhaul)
and Valve Rocker Arm Cover Removal - Right Side (See: Service and Repair/Overhaul) .
11. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod
Removal (See: Service and Repair/Overhaul) . 12. Remove the valve lifters. Refer to Valve Lifter
Removal (See: Service and Repair/Overhaul) . 13. Remove the oil pan-to-front cover bolts. 14.
Remove the front cover. Refer to Engine Front Cover Removal (See: Service and Repair/Overhaul)
. 15. Remove the camshaft retainer bolts (204) and retainer (203).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 3921
Notice: All camshaft journals are the same diameter, so care must be used in removing or installing
the camshaft to avoid damage to the camshaft bearings.
16. Remove the camshaft.
1. Install the camshaft sprocket bolt into the camshaft front bolt hole. 2. Using the bolt as a handle,
carefully rotate and pull the camshaft out of the engine block. 3. Remove the bolt from the front of
the camshaft.
Installation Procedure
Important: If camshaft replacement is required, the valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install the camshaft
sprocket bolt into the camshaft front bolt hole.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 3922
Notice: All camshaft journals are the same diameter, so care must be used in removing or installing
the camshaft to avoid damage to the camshaft bearings.
3. Using the bolt as a handle, carefully install the camshaft into the engine block. 4. Remove the
bolt from the front of the camshaft.
Important: The gasket surface on the engine block should be clean and free of dirt or debris.
5. Install the camshaft retainer (203) and the bolts (204). Install the retainer with the sealing gasket
facing the front of the engine block.
Notice: Refer to Fastener Notice .
6. Tighten the camshaft retainer bolts.
* Tighten the first design hex head bolts (3) to 25 N.m (18 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair > Page 3923
* Tighten the second design TORX(R) head bolts (4) to 15 N.m (11 lb ft).
7. Install the front cover. Refer to Engine Front Cover Installation (See: Service and
Repair/Overhaul) . 8. Install the oil pan-to-front cover bolts.
Tighten the bolts to 25 N.m (18 lb ft).
9. Install the valve lifters. Refer to Valve Lifter Installation (5.3L) (See: Service and
Repair/Overhaul) .
10. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod
Installation (See: Service and Repair/Overhaul) . 11. Install the left and right valve rocker arm
covers. Refer to Valve Rocker Arm Cover Installation - Left Side (See: Service and
Repair/Overhaul)
and Valve Rocker Arm Cover Installation - Right Side (See: Service and Repair/Overhaul) .
12. Install the coolant air bleed pipe. Refer to Engine Coolant Air Bleed Pipe and Hole Cover
Installation (See: Service and Repair/Overhaul) . 13. Install the valve lifter oil manifold. Refer to
Valve Lifter Oil Manifold Installation (See: Service and Repair/Overhaul) . 14. Install the intake
manifold. Refer to Intake Manifold Installation (See: Service and Repair/Overhaul) . 15. Install the
coolant pump manifold. Refer to Coolant Pump Manifold Replacement (See: Water Pump/Service
and Repair) . 16. Install the water pump. Refer to Water Pump Installation (See: Service and
Repair/Overhaul) . 17. Install the left and right exhaust manifolds. Refer to Exhaust Manifold
Installation - Left Side (See: Service and Repair/Overhaul) and Exhaust
Manifold Installation - Right Side (See: Service and Repair/Overhaul) .
18. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation (See: Service and
Repair/Overhaul) . 19. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation
(See: Service and Repair/Overhaul) . 20. Install the engine. Refer to Engine Replacement (See:
Service and Repair/Removal and Replacement/Engine Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Lifter / Lash Adjuster: Customer Interest Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3932
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3938
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement
Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Filter Replacement
Valve Lifter Oil Filter Replacement
Removal Procedure
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Intake Manifold/Service and Repair) . 2. Disconnect the oil pressure sensor electrical connector (4).
Important: Do not allow debris to enter the oil passages of the intake manifold.
3. Remove the oil pressure sensor (706) and washer (707). 4. Remove the oil filter (452) and
O-ring seal (454). 5. Inspect the O-ring seal (454) for cuts or damage. 6. If the filter is plugged or
the O-ring seal is cut or damaged, replace the filter and O-ring seal as an assembly.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3941
1. Install a NEW oil filter (452) and O-ring seal (454). 2. Apply sealant to the threads of the NEW oil
pressure sensor.
Notice: Refer to Fastener Notice .
3. Install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 20 N.m (15 lb ft).
4. Connect the oil pressure sensor electrical connector (4). 5. Install the engine sight shield. Refer
to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3942
Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Manifold Replacement
Valve Lifter Oil Manifold Replacement
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake
Manifold/Service and Repair) . 2. Do not lift the manifold assembly by the electrical lead frame.
3. Remove the valve lifter oil manifold bolts (506).
Important: Do not allow dirt or debris to enter the oil passages of the manifold. Plug as required.
4. Remove the valve lifter oil manifold (451).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3943
Important: Remove only the outer gasket from the manifold. Do not disassemble any of the internal
components of the manifold in an attempt to remove the eight inner sealing gaskets. If the inner
gaskets are cut or damaged, replace the manifold as an assembly. Only use a wire-cutter type tool
in order to minimize the amount of debris. Do not use a rotary-type cutting tool on the retaining
straps.
5. Identify the 8 gasket retaining strap locations (1-8).
6. Using a wire-cutter type tool, snip the 8 retaining straps of the outer gasket.
7. Remove the outer gasket (556) from the manifold.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3944
Installation Procedure
Important: All gasket surfaces should be free of oil or other foreign material during assembly.
1. Do not lift the manifold assembly by the electrical lead frame.
2. Install the outer gasket (556) onto the manifold.
3. Install the valve lifter oil manifold (451).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3945
Notice: Refer to Fastener Notice .
4. Install the valve lifter oil manifold bolts (506).
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service
and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3946
Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement
Valve Lifter Replacement
Special Tools
J 3049-A Valve Lifter Remover
Removal Procedure
1. Remove the cylinder head. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head
Assembly/Service and Repair) and/or Cylinder
Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair) .
2. Remove the lifter guide bolts (211).
Important: Note the installed position of the guides. The notched area of the guide is to align with
the locating tab of the block.
3. Remove the lifter guides (210) with lifters.
Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits.
4. Use the J 3049-A or equivalent in order to remove the valve lifters, if necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3947
5. Remove the valve lifters (209, 219) from the guide (210).
6. Organize or mark the components so that they can be installed in the same location from which
they were removed. The displacement on demand
lifters are installed into the guide by aligning the notched area of the guide (1) with the raised
surface on the side of the lifter (2).
7. Clean and inspect the valve lifters. Refer to Valve Lifter and Guide Cleaning and Inspection
(5.3L) (See: Service and Repair/Overhaul) .
Installation Procedure
Important:
* When reusing the valve lifters, install the lifters in their original locations.
*
If camshaft replacement is required, the valve lifters must also be replaced.
* Each of the four valve guide assemblies will contain two displacement on demand valve lifters
and two non-displacement on demand valve lifters.
* With the lifters and guides properly installed, cylinders 1, 4, 6, and 7 lifter bores will each contain
two displacement on demand valve lifters.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3948
1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides.
* Align the flat area (3) on the top of the non-displacement on demand lifter with the flat area in the
lifter guide bore.
* The displacement on demand lifters are to be installed into the guide, with the notch in the guide
(2) of the lifter.
3. Install the valve lifter guides (210) with lifters to the engine block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 3949
Notice: Refer to Fastener Notice .
4. Install the valve lifter guide bolts (211).
Tighten the bolts to 12 N.m (106 lb in).
5. Install the cylinder head. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head
Assembly/Service and Repair) and/or Cylinder
Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair
Push Rod: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Important: Place the valve rocker arm, pushrod, and pivot support, in a rack so that the can be
installed in the same location from which they were removed.
2. Remove the valve rocker arm bolt. 3. Remove the valve rocker arm.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrod. 6. Clean and inspect the valve rocker arm and pushrod. Refer to Valve
Rocker Arm and Push Rod Cleaning and Inspection (See: Service and
Repair/Overhaul) .
Installation Procedure
Important:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair > Page 3953
* When reusing the valve train components, always install the components to their original location
and position.
* Valve lash is net build, no valve adjustment is required.
1. Lubricate the valve rocker arm and pushrod with clean engine oil. 2. Lubricate the flange of the
valve rocker arm bolt with clean engine oil. 3. Install the valve rocker arm pivot support.
Important: Make sure that the pushrod seats properly to the valve lifter socket.
4. Install the pushrod.
Important: Ensure that the pushrod seat properly to the ends of the rocker arm. DO NOT tighten
the rocker arm bolt at this time.
5. Install the rocker arm and bolt. 6. Rotate the crankshaft until the number one piston is at top
dead center (TDC) of the compression stroke. In this position, cylinder number one
rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The
engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5, and 7 are the left bank. Cylinder 2, 4, 6,
and 8 are the right bank.
Notice: Refer to Fastener Notice .
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair > Page 3954
* Tighten cylinders 1, 2, 7, and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 1, 3, 4, and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts:
* Tighten cylinders 3, 4, 5, and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 2, 6, 7, and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Important: Place the valve rocker arm, pushrod, and pivot support, in a rack so that the can be
installed in the same location from which they were removed.
2. Remove the valve rocker arm bolt. 3. Remove the valve rocker arm.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrod. 6. Clean and inspect the valve rocker arm and pushrod. Refer to Valve
Rocker Arm and Push Rod Cleaning and Inspection (See: Service and
Repair/Overhaul) .
Installation Procedure
Important:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 3958
* When reusing the valve train components, always install the components to their original location
and position.
* Valve lash is net build, no valve adjustment is required.
1. Lubricate the valve rocker arm and pushrod with clean engine oil. 2. Lubricate the flange of the
valve rocker arm bolt with clean engine oil. 3. Install the valve rocker arm pivot support.
Important: Make sure that the pushrod seats properly to the valve lifter socket.
4. Install the pushrod.
Important: Ensure that the pushrod seat properly to the ends of the rocker arm. DO NOT tighten
the rocker arm bolt at this time.
5. Install the rocker arm and bolt. 6. Rotate the crankshaft until the number one piston is at top
dead center (TDC) of the compression stroke. In this position, cylinder number one
rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The
engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5, and 7 are the left bank. Cylinder 2, 4, 6,
and 8 are the right bank.
Notice: Refer to Fastener Notice .
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 3959
* Tighten cylinders 1, 2, 7, and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 1, 3, 4, and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts:
* Tighten cylinders 3, 4, 5, and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 2, 6, 7, and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting Rod Bearing Clearance - Production
........................................................................................................ 0.023-0.065 mm (0.0009-0.0025
in) Connecting Rod Bearing Clearance - Service
................................................................................................................ 0.023-0.076 mm
(0.0009-0.003 in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque
Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque
Bulletin No.: 07-06-01-002
Date: March 05, 2007
INFORMATION
Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV
Vortec(TM) V8 Engines
Models
A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV
Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using
two passes. The second pass value has been increased from 75 degrees to 85 degrees.
Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing
Installation in SI.
Tighten
Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft).
Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque > Page
3968
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Technical Service Bulletins > Page 3969
Connecting Rod: Specifications
Connecting Rod Bore Diameter - Bearing End
............................................................................................................ 56.505-56.525 mm
(2.224-2.225 in) Connecting Rod Bore Out-of-Round - Bearing End - Production
............................................................................. 0.004-0.008 mm (0.00015-0.0003 in) Connecting
Rod Bore Out-of-Round - Bearing End - Service
................................................................................... 0.004-0.008 mm (0.00015-0.0003 in)
Connecting Rod Side Clearance
........................................................................................................................................ 0.11-0.51
mm (0.00433-0.02 in)
Connecting Rod Bolts - First Pass .......................................................................................................
........................................................ 20 N.m (15 lb ft) Connecting Rod Bolts - Final Pass ..................
...................................................................................................................................................... 85
degrees
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications
Crankshaft Main Bearing: Specifications
Crankshaft Main Bearing Clearance - Production
......................................................................................................... 0.02-0.052 mm (0.0008-0.0021
in) Crankshaft Main Bearing Clearance - Service
............................................................................................................... 0.02-0.065 mm
(0.0008-0.0025 in)
Crankshaft Bearing Cap M8 Bolts
..............................................................................................................................................................
25 N.m (18 lb ft) Crankshaft Bearing Cap M10 Bolts - First Pass in Sequence
...................................................................................................................... 20 N.m (15 lb ft)
Crankshaft Bearing Cap M10 Bolts - Final Pass in Sequence
............................................................................................................................... 80 degrees
Crankshaft Bearing Cap M10 Studs - First Pass in Sequence
..................................................................................................................... 20 N.m (15 lb ft)
Crankshaft Bearing Cap M10 Studs - Final Pass in Sequence
.............................................................................................................................. 51 degrees
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Crankshaft
Connecting Rod Journal Diameter - Production
.................................................................................................. 53.318-53.338 mm (2.0991-2.0999
in) Connecting Rod Journal Diameter - Service
................................................................................................................................ 53.308 mm
(2.0987 in) Connecting Rod Journal Out-of-Round - Production
..................................................................................................................... 0.005 mm (0.0002 in)
Connecting Rod Journal Out-of-Round - Service
............................................................................................................................. 0.01 mm (0.0004
in) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production
...................................................................... 0.005 mm (0.0002 in) Connecting Rod Journal Taper Maximum for 1/2 of Journal Length - Service ........................................................................... 0.02
mm (0.00078 in) Crankshaft End Play
......................................................................................................................................................
0.04-0.2 mm (0.0015-0.0078 in) Crankshaft Main Journal Diameter - Production
..................................................................................................... 64.992-65.008 mm (2.558-2.559
in) Crankshaft Main Journal Diameter - Service
.................................................................................................................................. 64.992 mm
(2.558 in) Crankshaft Main Journal Out-of-Round - Production
................................................................................................................ 0.003 mm (0.000118 in)
Crankshaft Main Journal Out-of-Round - Service
.......................................................................................................................... 0.008 mm (0.0003 in)
Crankshaft Main Journal Taper - Production
................................................................................................................................... 0.01 mm
(0.0004 in) Crankshaft Main Journal Taper - Service
....................................................................................................................................... 0.02 mm
(0.00078 in) Crankshaft Rear Flange Runout
..........................................................................................................................................................
0.05 mm (0.002 in) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth
Diameter ..................................................................... 0.7 mm (0.028 in) Crankshaft Thrust Surface
- Production ..................................................................................................................... 26.14-26.22
mm (1.029-1.0315 in) Crankshaft Thrust Surface - Service
............................................................................................................................................... 26.22
mm (1.0315 in) Crankshaft Thrust Surface Runout
................................................................................................................................................... 0.025
mm (0.001 in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
Engine Block Heater: Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 3984
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 3985
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 3986
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 3987
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very
Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3993
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3994
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3995
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3996
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: >
07-08-50-009A > Jun > 10 > Interior - Front Power Seats Inop/Bind When Moving
Power Seat Drive Cable: All Technical Service Bulletins Interior - Front Power Seats Inop/Bind
When Moving
TECHNICAL
Bulletin No.: 07-08-50-009A
Date: June 08, 2010
Subject: Front Driver or Passenger Power Seat Inoperative/Binds When Moving Forward or
Rearward (Install Horizontal Seat Adjuster Cable/Shaft and Synchronize Seat Track)
Models:
2006-2010 Chevrolet Impala, Monte Carlo with RPOs AG1, AG2 or AH5
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 07-08-50-009 (Section 08 - Body and Accessories).
Condition
Some customers may comment that the driver or passenger front seat may not move forward or
backward or bind while moving forward or backward.
Cause
The horizontal seat adjuster cable may become dislodged from the adjuster. This may cause the
seat track assembly to become out of synchronization or inoperative.
Correction
Install the horizontal seat adjuster cable and synchronize the seat track assembly using the
following procedure:
1. Using the power seat switch, position the inoperative seat to the full up position. 2. Visually
inspect under the front seat to see if the horizontal cable (first longest cable) is dislodged from the
actuator or motor. 3. If the cable is installed properly and the seat track is inoperative, then do not
proceed to the next step. Refer to the Power Seat Inoperative
diagnostics in SI.
4. Inspect the loose cable end and make sure the end is not frayed or mushroomed. 5. If the cable
is not damaged, you can re-use the old cable and old clip. 6. If the cable end is damaged, you will
need to install a new cable, P/N 19124257, which will come with a new cable retainer clip. 7. Install
the cable by indexing the square end of the cable into the motor and/or the actuator.
Important The new style clip is not serviced separately, it will only come with the new cable.
8. Install the old clip or the new cable retainer clip onto the seat track frame bar (1) and secure the
cable retainer clip onto the second seat track frame
bar (2) as shown in the graphic above.
9. Move the seat to the full forward position using the power seat switch.
10. Unbolt the seat belt from the seat assembly. 11. Remove the two rear seat bolts.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: >
07-08-50-009A > Jun > 10 > Interior - Front Power Seats Inop/Bind When Moving > Page 4002
12. Remove the two rear plastic track trim covers. 13. Activate the power seat switch to the full
back position until the track stops.
Important Do not disconnect the power seat electrical connector.
14. Tilt the seat forward to release the seat from the two front retaining seat hooks. 15. Lay the seat
back assembly down towards the floor of the vehicle with the track bottom facing upward. Visually
inspect the adjusters and the drive
units.
16. Inspect the position of the drive units (1) to see if the units are bottom out against the adjuster
stops. 17. If both drive units are bottomed out against the adjuster stops, the inboard and outboard
tracks are synchronized and will function properly. No
further action is required - proceed to Step 19.
18. If there are any gaps between the adjuster stops and the drive units on either side, then the
tracks are not synchronized. This condition may cause
binding during seat track operation.
19. Determine which driver unit side is bottom out against the adjuster stop.
- If the outboard drive unit is bottomed out against the adjuster stop, follow these steps:
1. Remove the horizontal cable from the motor or actuator 2. Activate the power seat switch
forward until the inboard drive unit bottoms out against the adjuster stop. Both drive units should
now be at
the stops.
3. Reinstall the cable. The tracks are now synchronized.
- If the inboard drive unit is bottomed out against the adjuster stop, follow these steps:
1. Remove the horizontal cable from the motor or actuator 2. Activate the power seat switch
backward so that the inboard gap is greater than the outboard side gap. 3. Reinstall the cable. 4.
Activate the power seat switch forward until the outboard drive unit is against the adjuster stop.
20. Install the seat assembly. 21. Install the rear seat bolts.
Tighten Tighten the rear seat track bolts to 45 Nm(33 lb ft).
22. Install the rear seat track trim covers. 23. Install the seat belt and nut.
Tighten
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: >
07-08-50-009A > Jun > 10 > Interior - Front Power Seats Inop/Bind When Moving > Page 4003
Tighten the nut to 42 Nm(31 lb ft).
24. Verify the proper operation of the seat.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: >
07-08-50-009A > Jun > 10 > Interior - Front Power Seats Inop/Bind When Moving > Page 4009
12. Remove the two rear plastic track trim covers. 13. Activate the power seat switch to the full
back position until the track stops.
Important Do not disconnect the power seat electrical connector.
14. Tilt the seat forward to release the seat from the two front retaining seat hooks. 15. Lay the seat
back assembly down towards the floor of the vehicle with the track bottom facing upward. Visually
inspect the adjusters and the drive
units.
16. Inspect the position of the drive units (1) to see if the units are bottom out against the adjuster
stops. 17. If both drive units are bottomed out against the adjuster stops, the inboard and outboard
tracks are synchronized and will function properly. No
further action is required - proceed to Step 19.
18. If there are any gaps between the adjuster stops and the drive units on either side, then the
tracks are not synchronized. This condition may cause
binding during seat track operation.
19. Determine which driver unit side is bottom out against the adjuster stop.
- If the outboard drive unit is bottomed out against the adjuster stop, follow these steps:
1. Remove the horizontal cable from the motor or actuator 2. Activate the power seat switch
forward until the inboard drive unit bottoms out against the adjuster stop. Both drive units should
now be at
the stops.
3. Reinstall the cable. The tracks are now synchronized.
- If the inboard drive unit is bottomed out against the adjuster stop, follow these steps:
1. Remove the horizontal cable from the motor or actuator 2. Activate the power seat switch
backward so that the inboard gap is greater than the outboard side gap. 3. Reinstall the cable. 4.
Activate the power seat switch forward until the outboard drive unit is against the adjuster stop.
20. Install the seat assembly. 21. Install the rear seat bolts.
Tighten Tighten the rear seat track bolts to 45 Nm(33 lb ft).
22. Install the rear seat track trim covers. 23. Install the seat belt and nut.
Tighten
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: >
07-08-50-009A > Jun > 10 > Interior - Front Power Seats Inop/Bind When Moving > Page 4010
Tighten the nut to 42 Nm(31 lb ft).
24. Verify the proper operation of the seat.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement
Engine Block Heater: Service and Repair Coolant Heater Replacement
Coolant Heater Replacement (LS4) (5.3L)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining
and Filling (LZE, LZ4, LZG, Static Fill).
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Disconnect the
coolant heater cord from the coolant heater. 4. Remove the coolant heater (114) and washer (115).
5. Remove and clean any burrs, compound, paint, or rough spots from the core plug hole.
Installation Procedure
1. Apply a 3.175 mm (0.125 in) bead of sealant, GM P/N 12346004 (Canadian P/N 10953480) or
equivalent to the coolant heater.
Notice: Refer to Fastener Notice .
2. Install the coolant heater (114) and washer (115).
Tighten the coolant heater to 50 N.m (37 lb ft).
3. Connect the coolant heater cord to the coolant heater. 4. Lower the vehicle. 5. Fill the cooling
system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Cooling
System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining
and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 4013
Engine Block Heater: Service and Repair Coolant Heater Cord Replacement
Coolant Heater Cord Replacement (LS4) (5.3L)
Removal Procedure
1. Cut the tie strap attaching the coolant heater cord to the diagonal brace.
2. Cut the tie straps (1) attaching the coolant heater cord to the engine wiring harness. 3.
Disconnect the coolant heater cord connection from the coolant heater. 4. Remove the coolant
heater cord.
Installation Procedure
Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route
the cord to the left front of the engine compartment securing with tie straps as necessary to prevent
damage.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 4014
1. Install the coolant heater cord. 2. Connect the coolant heater cord connection to the coolant
heater. 3. Install NEW tie straps (1) attaching the coolant heater cord to the engine wiring harness.
4. Install a NEW tie strap attaching the coolant heater cord to the diagonal brace.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Balancer Bolt - Installation Pass to Ensure the Balancer is Completely Installed
................................................................. 330 N.m (240 lb ft) Crankshaft Balancer Bolt - First Pass Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final
Passes .............. 50
N.m (37 lb ft)
Crankshaft Balancer Bolt - Final Pass .................................................................................................
................................................................ 140 degrees
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 4018
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Balancer Replacement
Tools Required
* EN 47699 Flywheel Holding Tool
* J 41665 Crankshaft Balancer and Sprocket Installer
* J 41816 Crankshaft Balancer Remover
* J 41816-2 Crankshaft End Protector
* J 42640 Steering Column Anti-Rotation Pin
* J 45059 Torque Angle Meter
Removal Procedure
1. Install a J 42640 . Refer to Steering Column Replacement . 2. Remove the accessory drive belt.
Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts, Brackets and
Accessories/Drive
Belt/Service and Repair) .
3. Remove the air cleaner upper housing. Refer to Air Cleaner Assembly Replacement . 4. Remove
the engine mount strut. Refer to Engine Mount Strut Replacement (See: Drive Belts, Mounts,
Brackets and Accessories/Engine
Mount/Service and Repair) .
5. Remove the starter motor. Refer to Starter Motor Replacement (LS4) Starter Motor Replacement
(RPOs LZE/LZ4/LZ8) . 6. Remove the front fender splash shield. 7. Disconnect the transaxle cooler
lines at the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and
Connection .
8. Remove the stabilizer shaft link lower nuts. Refer to Stabilizer Shaft Link Replacement . 9.
Remove the intermediate steering shaft pinch bolt and separate the shaft from the steering gear.
Refer to Intermediate Steering Shaft Replacement
.
10. Remove the front lower air deflector braces and the deflector. Refer to Radiator Air Lower
Baffle and Deflector Replacement (See: Cooling
System/Radiator/Service and Repair) .
11. Remove the radiator to frame braces. 12. Install the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) . 13.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 14. Remove the
frame-to-body bolts. 15. Remove the transmission-to-engine bolt located at approximately the 10
o'clock position when looking from the rear of the engine.
Notice: Refer to Fastener Notice .
16. Install the EN 47699 and bolt to the block and flywheel.
Tighten the bolt to 60 N.m (44 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 4019
17. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation . 18. Lower the engine approximately 100 mm (4 in).
19. Remove the crankshaft balancer bolt (139).
Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer
installation procedure.
20. Install the J 41816 (1) and the J 41816-2 (2), to the crankshaft balancer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 4020
21. Remove the crankshaft balancer (138). 22. Remove the J 41816 and the J 41816-2 from the
crankshaft balancer.
Installation Procedure
Important:
* The used crankshaft balancer bolt will be used only during the first pass of the balancer
installation procedure. Install a NEW bolt and tighten as described in the second, third and forth
passes of the balancer bolt tightening procedure.
* The crankshaft balancer installation and bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed completely onto the crankshaft. The second,
third, and forth passes tighten the new bolt to the proper torque.
* The balancer should be positioned onto the end of the crankshaft as straight as possible prior to
tool installation.
1. Position the crankshaft balancer (138) onto the end of the crankshaft.
2. Using the J 41665 , install the crankshaft balancer.
1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into
the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a
second wrench and rotate the installation tool nut clockwise until the balancer is started onto the
crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the
installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded
rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is
installed onto the crankshaft. 7. Remove the balancer installation tool.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 4021
Notice: Refer to Fastener Notice .
3. Install the USED crankshaft balancer bolt (139).
Tighten the USED bolt to 330 N.m (240 lb ft).
4. Remove the USED crankshaft balancer bolt.
Important: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the
balancer bore.
5. Measure for a correctly installed balancer. If the balancer is not installed to the proper
dimensions, install the J 41665 and repeat the installation
procedure.
6. Install a NEW crankshaft balancer bolt (139).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 4022
* Tighten the bolt a first pass to 50 N.m (37 lb ft).
* Tighten the bolt a second pass to 140 degrees using J 45059 .
7. Remove the EN 47699 and bolt from the block and flywheel. 8. Install the transmission
bellhousing bolt located at approximately the 10 o'clock position when looking from the rear of the
engine.
Tighten the bolt to 75 N.m (55 lb ft).
9. Raise and properly position the frame and install the frame to body bolts. Refer to Frame
Replacement .
10. Install the frame to radiator braces. 11. Install the front lower air deflector. Refer to Radiator Air
Lower Baffle and Deflector Replacement (See: Cooling System/Radiator/Service and
Repair) .
12. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering
Shaft Replacement . 13. Install the stabilizer shaft link lower nuts. Refer to Stabilizer Shaft Link
Replacement . 14. Connect the transaxle cooler lines to the transaxle. Refer to Transmission Fluid
Cooler Hose/Pipe Quick-Connect Fitting Disconnection and
Connection .
15. Remove the engine support fixture. 16. Install the front fender splash shield. 17. Install the
starter motor. Refer to Starter Motor Replacement (LS4) Starter Motor Replacement (RPOs
LZE/LZ4/LZ8) . 18. Install the air cleaner upper housing. Refer to Air Cleaner Assembly
Replacement . 19. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory
(See: Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair) .
20. Install the engine mount strut. Refer to Engine Mount Strut Replacement (See: Drive Belts,
Mounts, Brackets and Accessories/Engine
Mount/Service and Repair) .
21. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
. 22. Perform the crankshaft position (CKP) system variation learn procedure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston - Piston Diameter - Measured Over Skirt Coating
........................................................................................ 96.002-96.036 mm (3.7796-3.7809 in)
Piston - Piston to Bore Clearance - Production
............................................................................................. -0.036 to +0.016 mm (-0.0014 to
+0.0006 in) Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off
................................................................................ 0.071 mm (0.0028 in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Pin - Piston Pin Clearance-to-Piston Pin Bore - Production
...................................................................................... 0.002-0.01 mm (0.00008-0.00004 in) Pin Piston Pin Clearance-to-Piston Pin Bore - Service
............................................................................................ 0.002-0.015 mm (0.00008-0.0006 in) Pin
- Piston Pin Fit in Connecting Rod Bore - Production
......................................................................................... 0.007-0.02 mm (0.00027-0.00078 in) Pin Piston Pin Fit in Connecting Rod Bore - Service
............................................................................................ 0.007-0.022 mm (0.00027-0.00086 in)
Pin - Piston Pin Diameter
.........................................................................................................................................
23.952-23.955 mm (0.9430-0.9431 in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Rings
Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production
........................................... 0.23-0.44 mm (0.009-0.017 in) Piston Ring End Gap - First
Compression Ring - Measured in Cylinder Bore - Service ................................................. 0.23-0.5
mm (0.009-0.0196 in) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder
Bore - Production ......................................... 0.44-0.7 mm (0.017-0.027 in) Piston Ring End Gap Second Compression Ring - Measured in Cylinder Bore - Service .............................................
0.44-0.76 mm (0.0173-0.03 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore
- Production ...................................................... 0.18-0.75 mm (0.007-0.029 in) Piston Ring End
Gap - Oil Control Ring - Measured in Cylinder Bore - Service ............................................................
0.18-0.81 mm (0.007-0.032 in) Piston Ring to Groove Clearance - First Compression Ring Production ............................................................. 0.04-0.085 mm (0.00157-0.00335 in) Piston
Ring to Groove Clearance - First Compression Ring - Service
................................................................... 0.04-0.085 mm (0.00157-0.00335 in) Piston Ring to
Groove Clearance - Second Compression Ring - Production ...........................................................
0.04-0.078 mm (0.00157-0.0031 in) Piston Ring to Groove Clearance - Second Compression Ring
- Service ................................................................ 0.04-0.078 mm (0.00157-0.0031 in) Piston Ring
to Groove Clearance - Oil Control Ring - Production
.............................................................................. 0.012-0.2 mm (0.0005-0.0078 in) Piston Ring to
Groove Clearance - Oil Control Ring - Service ....................................................................................
0.012-0.2 mm (0.0005-0.0078 in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate >
Component Information > Service and Repair
Rear Engine Plate: Service and Repair
Engine Rear Cover Replacement
Tools Required
J 41476 Front and Rear Cover Alignment Tool (at crankshaft seal area)
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) . 2. Remove the oil pan-to-rear cover bolts. 3. Remove
the rear cover bolts (517). 4. Remove the rear cover (518) and gasket (519). Discard the gasket. 5.
Remove and discard the rear oil seal (141).
Installation Procedure
Important:
* Do not reuse the crankshaft oil seal or rear cover gasket.
* Do not apply any type of sealant to the rear cover gasket, unless specified.
* The special tool in this procedure is used to properly center the crankshaft rear oil seal.
* The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned.
Install the rear cover without the crankshaft oil seal.
- All gasket surfaces should be free of oil or other foreign material during assembly.
- The crankshaft rear oil seal MUST be centered in relation to the crankshaft.
- An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly
oil leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate >
Component Information > Service and Repair > Page 4035
1. Apply a 5 mm (0.20 in) bead of sealant or equivalent 20 mm (0.80 in) long, to the oil pan to
engine block junction. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the
correct part number.
2. Install the rear cover gasket (519) and cover (518). 3. Install the rear cover bolts (517) until snug.
Do not overtighten. 4. Install the oil pan-to-rear cover bolts until snug. Do not overtighten.
5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface.
Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the crankshaft.
Notice: Refer to Fastener Notice .
7. Tighten the J 41476 mounting bolts until snug. Do not overtighten.
1. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). 2. Tighten the engine rear cover
bolts to 30 N.m (22 lb ft).
8. Remove the J 41476 . 9. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil
Seal Replacement (See: Seals and Gaskets/Crankshaft Main Bearing
Seal/Service and Repair) .
10. Install the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 4041
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 4042
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 4043
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker Arm Cover Replacement - Right
Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Important: Place the valve rocker arm, pushrod, and pivot support, in a rack so that the can be
installed in the same location from which they were removed.
2. Remove the valve rocker arm bolt. 3. Remove the valve rocker arm.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrod. 6. Clean and inspect the valve rocker arm and pushrod. Refer to Valve
Rocker Arm and Push Rod Cleaning and Inspection (See: Service and
Repair/Overhaul) .
Installation Procedure
Important:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair > Page 4047
* When reusing the valve train components, always install the components to their original location
and position.
* Valve lash is net build, no valve adjustment is required.
1. Lubricate the valve rocker arm and pushrod with clean engine oil. 2. Lubricate the flange of the
valve rocker arm bolt with clean engine oil. 3. Install the valve rocker arm pivot support.
Important: Make sure that the pushrod seats properly to the valve lifter socket.
4. Install the pushrod.
Important: Ensure that the pushrod seat properly to the ends of the rocker arm. DO NOT tighten
the rocker arm bolt at this time.
5. Install the rocker arm and bolt. 6. Rotate the crankshaft until the number one piston is at top
dead center (TDC) of the compression stroke. In this position, cylinder number one
rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. The
engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5, and 7 are the left bank. Cylinder 2, 4, 6,
and 8 are the right bank.
Notice: Refer to Fastener Notice .
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair > Page 4048
* Tighten cylinders 1, 2, 7, and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 1, 3, 4, and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts:
* Tighten cylinders 3, 4, 5, and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten cylinders 2, 6, 7, and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker Arm Cover Replacement - Right
Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side
Valve Rocker Arm Cover Replacement - Left Side
Removal Procedure
1. Remove the engine sight shield, if required. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Intake Manifold/Service and Repair)
.
2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the ignition coil main
electrical connector (4). 4. Reposition the engine harness, as necessary.
5. Remove the spark plug wires (724) from the ignition coils.
1. Twist each plug wire 1/2 turn. 2. Pull only on the boot in order to remove the wire from the
ignition coil.
6. Remove the ignition coil bracket bolts (720). 7. Remove the ignition coil and bracket assembly
(719).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4053
8. Remove the positive crankcase ventilation (PCV) clean air tube from the valve rocker arm cover.
9. Remove the valve rocker arm cover bolts and cover.
10. Remove and discard the old the gasket (504) from the valve rocker arm cover. 11. Remove the
valve rocker arm cover bolt grommets, if cut or damaged.
Important: Do not remove the oil fill tube from the rocker cover unless service is required. If the oil
fill tube has been removed, install a NEW tube during assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4054
12. Remove the oil fill cap from the oil fill tube, if necessary. 13. Remove the oil fill tube, if
necessary. 14. Discard the oil fill tube, if necessary.
Installation Procedure
Important:
* All gasket surfaces should be free of oil an/or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
* The valve rocker arm cover bolt grommets may be reused.
1. Install a NEW gasket (504) into the groove of the valve rocker arm cover.
2. Install a NEW oil fill tube to the valve rocker arm cover, if necessary. 3. Install NEW valve rocker
arm cover bolt grommets, if necessary.
Notice: Refer to Fastener Notice .
4. Install the valve rocker arm cover and bolts.
Tighten the bolts to 12 N.m (106 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4055
5. Remove the positive crankcase ventilation (PCV) clean air tube from the valve rocker arm cover.
6. Apply threadlock to the threads of the ignition coil bracket bolts. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See:
Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
7. Install the ignition coil and bracket assembly. 8. Install the ignition coil bracket bolts.
Tighten the bolts to 12 N.m (106 lb in).
9. Install the spark plug wires (724) to the ignition coils.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4056
10. Position the engine harness, as necessary. 11. Connect the ignition coil main electrical
connector (4). 12. Install the CPA retainer (3). 13. Install the engine sight shield, if required. Refer
to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4057
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side
Valve Rocker Arm Cover Replacement - Right Side
Removal Procedure
1. Remove the engine sight shield, if required. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Intake Manifold/Service and Repair)
.
2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the ignition coil main
electrical connector (4). 4. Reposition the engine harness, if necessary.
5. Remove the spark plug wires (724) from the ignition coils.
1. Twist each plug wire 1/2 turn. 2. Pull only on the boot in order to remove the wire from the
ignition coil.
6. Remove the ignition coil bracket bolts (720). 7. Remove the ignition coil and bracket assembly
(719).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4058
8. Remove the positive crankcase ventilation (PCV) foul air hose from the intake manifold and
valve rocker arm cover.
9. Remove the valve rocker arm cover bolts and cover.
10. Remove and discard the old the gasket (504) from the valve rocker arm cover. 11. Remove the
valve rocker arm cover bolt grommets, if cut or damaged.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4059
Important:
* All gasket surfaces should be free of oil or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
* The valve rocker arm cover bolt grommets may be reused.
1. Install a NEW gasket (504) into the groove of the valve rocker arm cover.
2. Install NEW valve rocker arm cover bolt grommets, if necessary. 3. Install the valve rocker arm
cover and bolts.
Notice: Refer to Fastener Notice .
4. Install the rocker arm cover bolts and grommets.
Tighten the bolts to 12 N.m (106 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4060
5. Install the PCV foul air hose to the intake manifold and valve rocker arm cover.
6. Apply threadlock to the threads of the ignition coil bracket bolts. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See:
Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
7. Install the ignition coil and bracket assembly (719). 8. Install the ignition coil bracket bolts (720).
Tighten the bolts to 12 N.m (106 lb in).
9. Install the spark plug wires (724) from the ignition coils.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 4061
10. Position the engine harness, if necessary. 11. Connect the ignition coil main electrical
connector (4). 12. Install the CPA retainer (3). 13. Install the engine sight shield, if required. Refer
to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions
Valve Spring: Service Precautions
Valve Springs Can Be Tightly Compressed Caution
Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs.
Personal injury could result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 4065
Valve Spring: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Tools Required
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Rocker Arm Assembly/Service and Repair) .
Important: Remove the spark plugs from the cylinder head with the engine at room temperature.
2. Loosen the spark plug 1 or 2 turns. 3. Brush or air blast away any dirt or debris from around the
spark plug. 4. Remove the spark plug.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 4066
5. Install the J 22794 into the spark plug hole. 6. Attach an air hose to the J 22794 . 7. Apply
compressed air to the J 22794 in order to hold the valves in place.
8. Using the J 38606 compress the valve spring.
9. Remove the valve stem keys (225).
10. Using the J 38606 carefully release the valve spring tension. 11. Remove the J 38606 . 12.
Remove the valve spring cap (224). 13. Remove the valve spring (223). 14. Remove the valve
stem oil seal (222) .
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 4067
1. Clean the cylinder head valve spring seat and area. 2. Install the valve stem oil seal (222). 3.
Install the valve spring (223). 4. Install the valve spring cap (224).
5. Compress the valve spring using the J 38606 . 6. Install the valve stem keys.
1. Use grease in order to hold the valve stem keys in place. 2. Make sure the keys seat properly in
the groove of the valve stem. 3. Using the J 38606 carefully release the valve spring tension,
making sure the valve stem keys stay in place. 4. Remove the J 38606 . 5. Tap the end of the valve
stem with a plastic faced hammer to seat the keys, if necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 4068
7. Remove the compressed air supply from the J 22794 . 8. Remove the J 22794 from the spark
plug port.
Notice: Refer to Fastener Notice .
9. Hand start the spark plug.
Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Rocker Arm Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page
4074
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page
4075
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 4076
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 4077
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the pulleys. The drive belts are made of different
types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or
3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility
that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent
should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the
back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not
be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is
to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the
pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or
3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct
diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive
belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4080
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4081
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4082
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell
off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a
misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4083
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4084
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the A/C system over charged, the power steering
system restricted or the incorrect fluid, or an extra load on the generator. To help identify an
intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
4085
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Page 4086
Drive Belt: Service and Repair
Drive Belt Replacement - Accessory
Tools Required
EN-47988 Serpentine Belt Tension Unloader
Removal Procedure
1. Remove the passenger side diagonal brace, if more clearance is required. Refer to Front Fender
Upper Diagonal Brace Replacement . 2. Reposition the underhood bussed electrical center
(UBEC), if more clearance is required. 3. Install the EN-47988 , to the drive belt tensioner. 4.
Rotate the EN-47988 clockwise in order to relieve the tension on the belt tensioner.
5. Remove the drive belt (1) from over the power steering pump pulley.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Page 4087
6. Slowly release the EN-47988 . 7. Remove the EN-47988 from the belt tensioner. 8. Remove the
drive belt (1) from around all the other pulleys. 9. Clean and inspect the belt surfaces of all the
pulleys.
Installation Procedure
1. Install and route the drive belt around all the pulleys except for the power steering pump pulley.
2. Ensure that when installing the EN-47988 (1), to the belt tensioner that the EN-47988 is NOT
installed above the drive belt (2).
3. Ensure that when installing the EN-47988 (1), to the belt tensioner that the EN-47988 is installed
below the drive belt (2). 4. Rotate the EN-47988 clockwise in order to relieve the tension on the belt
tensioner. 5. Ensure that the drive belt is still properly routed around all the other pulleys, then
install the drive belt over the power steering pump pulley. 6. Slowly release the EN-47988 . 7.
Remove the EN-47988 from the belt tensioner. 8. Inspect the drive belt for proper installation and
alignment. 9. Position the UBEC, if required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Testing and Inspection > Page 4088
10. Install the passenger side diagonal brace, if required. Refer to Front Fender Upper Diagonal
Brace Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection
Drive Belt Tensioner: Testing and Inspection
Drive Belt Tensioner Diagnosis
Inspection Procedure
Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the
tensioner.
Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the
drive belt tensioner because of movement in the drive belt tensioner arm.
1. Remove the drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service
and Repair) . 2. Move the drive belt tensioner through its full travel.
* The movement should feel smooth.
* There should be no binding.
* The tensioner should return freely.
3. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Replacement Accessory (See: Drive Belt/Service and Repair) . 4. Install the drive belt. Refer to of Drive Belt
Replacement - Accessory (See: Drive Belt/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection > Page 4092
Drive Belt Tensioner: Service and Repair
Drive Belt Tensioner Replacement - Accessory
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair) . 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
. 3. Remove the right wheel and tire. Refer to Tire and Wheel Removal and Installation . 4. Remove
the right engine splash shield. 5. Remove the power steering gear inlet hose retainer bolt (2).
6. Remove the drive belt tensioner bolts. 7. Remove the drive belt tensioner.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Testing and Inspection > Page 4093
1. Install the drive belt tensioner.
Notice: Refer to Fastener Notice .
2. Install the drive belt tensioner bolts.
Tighten the bolts to 50 N.m (37 lb ft).
3. Install the power steering gear inlet hose retainer bolt (2).
Tighten the bolt to 9 N.m (80 lb in).
4. Install the right engine splash shield. 5. Install the right wheel and tire. Refer to Tire and Wheel
Removal and Installation . 6. Lower the vehicle. 7. Install the accessory drive belt. Refer to Drive
Belt Replacement - Accessory (See: Drive Belt/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Testing and Inspection
Engine Mount: Testing and Inspection
Engine Mount Inspection
Inspection Procedure
Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of
the fluid is the engine mount, not the engine or accessories.
1. Install the engine support fixture. Refer to Engine Support Fixture (See: Service and
Repair/Removal and Replacement/Engine Support Fixture) . 2. Raise the engine in order to
remove the weight from the engine mount and to create slight tension in the rubber. 3. Observe the
engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any
of the following conditions:
* The hard rubber surface is covered with heat check cracks.
* The rubber is separated from the metal plate of the engine mount.
* The rubber is split through the center of the engine mount.
4. If there is movement between the metal plate of the engine mount and its attaching points, lower
the engine on the engine mount. Tighten the bolts
or nuts attaching the engine mount to the frame or engine mount bracket.
5. For information on the transaxle mount, refer to Transmission Mount Inspection .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left
Engine Mount: Service and Repair Engine Mount Bracket Replacement - Left
Engine Mount Bracket Replacement - Left Side
Removal Procedure
1. Remove the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) . 2. Remove
the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (RPO LS4) (See:
Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Left Side)Exhaust Manifold
Replacement - Left Side (RPOs LZE/LZ4/LZ8) (See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Left Side) .
3. Remove the upper engine mount nuts. 4. Install the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) . 5.
Using the engine support fixture, raise the engine .
6. Remove the engine mount bracket bolts. 7. Remove the engine mount bracket.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4099
1. Install the engine mount bracket.
Notice: Refer to Fastener Notice .
2. Install the engine mount bracket bolts.
Tighten the bolts to 50 N.m (37 lb ft).
3. Using the engine support fixture, lower the engine . 4. Remove the engine support fixture. 5.
Install the upper engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
6. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (RPO LS4)
(See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Left Side)Exhaust Manifold Replacement - Left Side
(RPOs LZE/LZ4/LZ8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust
Manifold Replacement - Left Side) .
7. Install the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4100
Engine Mount: Service and Repair Engine Mount Bracket Replacement - Right
Engine Mount Bracket Replacement - Right Side
Removal Procedure
1. Remove the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) . 2. Remove
the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (RPO LS4) (See:
Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side)Exhaust Manifold
Replacement - Right Side (RPOs LZE/LZ4/LZ8) ( See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Right Side) .
3. Remove the upper engine mount nuts. 4. Install the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) . 5.
Using the engine support fixture, raise the engine .
6. Remove the engine mount bracket bolts. 7. Remove the engine mount bracket.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4101
1. Install the engine mount.
Notice: Refer to Fastener Notice .
2. Install the lower engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
3. Using the engine support fixture, lower the engine . 4. Remove the engine support fixture. 5.
Install the upper engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
6. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (RPO
LS4) (See: Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side)Exhaust Manifold
Replacement - Right Side (RPOs LZE/LZ4/LZ8) ( See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Right Side) .
7. Install the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4102
Engine Mount: Service and Repair Engine Mount Replacement - Left
Engine Mount Replacement - Left Side
Removal Procedure
1. Remove the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) . 2. Remove
the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (RPO LS4) (See:
Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Left Side)Exhaust Manifold
Replacement - Left Side (RPOs LZE/LZ4/LZ8) (See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Left Side) .
3. Remove the upper engine mount nuts. 4. Install the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) . 5.
Using the engine support fixture, raise the engine .
6. Remove the engine mount bracket bolts. 7. Remove the engine mount bracket. 8. Raise and
support the vehicle. Refer to Lifting and Jacking the Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4103
9. Remove the lower engine mount nuts.
10. Remove the engine mount. 11. Remove the engine mount heat shield, if necessary.
Installation Procedure
1. Install the engine mount heat shield, if necessary. 2. Install the engine mount to the engine.
Notice: Refer to Fastener Notice .
3. Install the lower engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
4. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4104
5. Install the engine mount bracket. 6. Install the engine mount bracket bolts.
Tighten the bolts to 50 N.m (37 lb ft).
7. Using the engine support fixture, lower the engine . 8. Remove the engine support fixture. 9.
Install the upper engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
10. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (RPO LS4)
(See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Left Side)Exhaust Manifold Replacement - Left Side
(RPOs LZE/LZ4/LZ8) (See: Exhaust System/Exhaust Manifold/Service and Repair/Exhaust
Manifold Replacement - Left Side) .
11. Install the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4105
Engine Mount: Service and Repair Engine Mount Replacement - Right
Engine Mount Replacement - Right Side
Removal Procedure
1. Remove the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) . 2. Remove
the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (RPO LS4) (See:
Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side)Exhaust Manifold
Replacement - Right Side (RPOs LZE/LZ4/LZ8) ( See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Right Side) .
3. Remove the upper engine mount nuts. 4. Install the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) . 5.
Using the engine support fixture, raise the engine .
6. Remove the engine mount bracket bolts. 7. Remove the engine mount bracket. 8. Raise and
support the vehicle. Refer to Lifting and Jacking the Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4106
9. Remove the lower engine mount nuts.
10. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
Notice: Refer to Fastener Notice .
2. Install the lower engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
3. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4107
4. Install the engine mount bracket. 5. Install the engine mount bracket bolts.
Tighten the bolts to 50 N.m (37 lb ft).
6. Using the engine support fixture, lower the engine . 7. Remove the engine support fixture. 8.
Install the upper engine mount nuts.
Tighten the nuts to 50 N.m (37 lb ft).
9. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (RPO
LS4) (See: Exhaust System/Exhaust
Manifold/Service and Repair/Exhaust Manifold Replacement - Right Side)Exhaust Manifold
Replacement - Right Side (RPOs LZE/LZ4/LZ8) ( See: Exhaust System/Exhaust Manifold/Service
and Repair/Exhaust Manifold Replacement - Right Side) .
10. Install the engine mount strut. Refer to Engine Mount Strut Replacement (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4108
Engine Mount: Service and Repair Engine Mount Strut Replacement
Engine Mount Strut Replacement
Removal Procedure
1. Remove the forward engine mount strut bolt (3) and nut (1). 2. Remove the rear engine mount
strut bolt (4) and nut (5). 3. Remove the engine mount strut (2). 4. Inspect the rubber in the engine
mount strut for the following conditions:
* Hardness
* Splitting
* Cracking
5. If necessary, remove the engine mount strut bracket bolts (body side). 6. If necessary, remove
the engine mount strut bracket (body side).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4109
7. Remove the heater pipe bracket bolt from the engine mount. 8. If necessary, remove the engine
mount strut bracket bolts (engine side). 9. If necessary, remove the engine mount strut bracket
(engine side).
Installation Procedure
1. If necessary, position the engine mount strut bracket (engine side) to the cylinder head.
Notice: Refer to Fastener Notice .
2. If necessary, install the engine mount strut bracket bolts (engine side).
Tighten the bolts to 48 N.m (35 lb ft).
3. Install the heater pipe bracket bolt.
Tighten the bolt to 16 N.m (12 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 4110
4. If necessary, position the engine mount strut bracket (body side) to the vehicle. 5. If necessary,
install the engine mount strut bracket bolts (body side).
Tighten the bolt to 48 N.m (35 lb ft).
6. Install the engine mount strut (2). 7. Install the rear engine mount strut bolt (4) and nut (5).
Tighten the bolt/nut to 48 N.m (35 lb ft).
8. Install the forward engine mount strut bolt (3) and nut (1).
Tighten the bolt/nut to 48 N.m (35 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair
Idler Pulley: Service and Repair
Drive Belt Idler Pulley Replacement
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair) . 2. Loosen the necessary drive belt idler pulley bolt. 3. Remove the
necessary drive belt idler pulley.
Installation Procedure
1. Position the necessary drive belt idler pulley to the coolant manifold and/or generator bracket.
Notice: Refer to Fastener Notice .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Page 4114
2. Tighten the necessary drive belt idler pulley bolt.
Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and
Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure - Minimum Hot
1,000 engine RPM ...............................................................................................................................
....................................................... 6 psig (41 kPa) 2,000 engine RPM ..............................................
.................................................................................................................................... 18 psig (124
kPa) 4,000 engine RPM ......................................................................................................................
............................................................ 24 psig (165 kPa)
Active Fuel Management Relief Valve - RPO LC9, LMG, LH6, L76
Oil Pressure .........................................................................................................................................
...................... 55-75 psig (379-517 kPa) Min-Max.
NOTE: As Measured at Oil Pressure Sensor Location.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 4119
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant In Engine Oil) .
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
following conditions:
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul) .
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul) .
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul) .
* Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder
Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See:
Testing and Inspection/Component Tests and General Diagnostics) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube Replacement
Removal Procedure
1. Remove the oil level indicator (418) from the tube. 2. Remove the oil level indicator tube bolt
(419). 3. Remove the oil level indicator tube (420) from the engine block.
Important: Inspect the O-ring for cuts or damage. The seal may be reused if it is not cut or
damaged.
4. Remove the O-ring seal from the tube, if necessary.
Installation Procedure
1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal onto the oil level
indicator tube, if necessary. 3. Install the oil level indicator tube (420) to the engine block. The tube
must be installed with the collar flush to the block.
Notice: Refer to Fastener Notice .
4. Install the oil level indicator tube bolt (419)
Tighten the bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator (418) to the tube.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick
Noise At Start Up
Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick
Noise At Start Up > Page 4131
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 >
Engine - GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 >
Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 4137
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 >
Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 4138
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 >
Engine - Valve Lifter Tick Noise At Start Up
Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 >
Engine - Valve Lifter Tick Noise At Start Up > Page 4143
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine GM dexos 1 and dexos 2(R) Oil Specifications > Page 4149
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine GM dexos 1 and dexos 2(R) Oil Specifications > Page 4150
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil with Filter ............................................................................................................................
............................................... 6.0 quarts (5.7 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 4153
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE Look for two things:
1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M.
2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 4154
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 4155
Notice: Refer to Fastener Notice .
Important: Prior to installing a NEW oil filter, ensure that the old oil filter gasket has been removed
from the engine block. If not, remove the old gasket.
1. Install a NEW engine oil filter (437).
Tighten the filter to 30 N.m (22 lb ft).
2. Install the oil pan drain plug (430) and O-ring (429).
Tighten the drain plug to 25 N.m (18 lb ft).
3. Lower the vehicle. 4. Fill the engine with the appropriate amount and type of NEW engine oil.
Refer to Approximate Fluid Capacities and Fluid and Lubricant
Recommendations .
5. Check the oil level. 6. Install the oil fill cap. 7. Close the hood. 8. Reset the engine oil life monitor,
if necessary. Refer to GM Oil Life System Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve >
Component Information > Service and Repair
Engine Oil Control Valve: Service and Repair
Oil Pressure Relief Valve Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve >
Component Information > Service and Repair > Page 4159
7. Remove the oil pan cover bolts. 8. Remove the valve lifter oil pressure relief valve (455).
Installation Procedure
1. Install the valve lifter oil pressure relief valve (455).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve >
Component Information > Service and Repair > Page 4160
2. Inspect the valve lifter oil pressure relief valve for proper operation. Lightly depress the valve (2).
The valve spring (1) should seat the valve to the
proper closed position.
Notice: Refer to Fastener Notice .
3. Install the oil pan cover bolts and cover.
Tighten the bolts to 12 N.m (106 lb in).
4. Install a NEW engine oil filter (437).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve >
Component Information > Service and Repair > Page 4161
5. Install the oil pan drain plug (430) and O-ring (429). 6. Lower the vehicle. 7. Fill the engine with
the appropriate amount and type of NEW engine oil. Refer to Approximate Fluid Capacities and
Fluid and Lubricant
Recommendations .
8. Check the oil level. 9. Install the oil fill cap.
10. Open the hood. 11. Reset the engine oil lift monitor, if necessary. Refer to GM Oil Life System
Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Removal Procedure
1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in
order to rotate the retaining ring. 2. Rotate the retaining ring around the quick connector until the
retaining ring is out of position and can be completely removed. 3. Remove the engine oil cooler
line from the quick connector fitting.
Pull the lines straight out from the connector.
4. Clean all of the components in a suitable solvent, and dry them with compressed air. 5. Inspect
the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction.
Replace parts as necessary.
Installation Procedure
Important: Do not install the new retaining ring onto the fitting by pushing the retaining ring down
over the fitting.
1. Install the retaining ring into each quick connector fitting.
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4166
3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears
through the 3 slots.
4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining
ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting.
Pull back on the engine oil cooler lines to ensure a proper connection.
6. Inspect and fill the engine oil to the proper level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4167
Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement
Engine Oil Cooler Hose/Pipe Replacement
Removal Procedure
1. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement (Right)
Engine Splash Shield Replacement (Left) . 2. Remove the lower air baffle. Refer to Radiator Air
Lower Baffle and Deflector Replacement (See: Cooling System/Radiator/Service and Repair) . 3.
Remove the support clip from the engine oil cooler lines.
4. Remove the engine oil cooler lines from the engine oil cooler. Refer to Engine Oil Cooler
Pipe/Hose Quick Connect Fitting (See: Engine Oil
Cooler Pipe/Hose Quick Connect Fitting) .
5. Remove the engine oil cooler lines from the engine oil filter adapter. Refer to Engine Oil Cooler
Pipe/Hose Quick Connect Fitting (See: Engine
Oil Cooler Pipe/Hose Quick Connect Fitting) .
6. Remove the engine oil cooler lines from the vehicle.
Installation Procedure
1. Install the engine oil cooler lines to the vehicle.
2. Install the engine oil cooler lines to the engine oil cooler. Refer to Engine Oil Cooler Pipe/Hose
Quick Connect Fitting (See: Engine Oil Cooler
Pipe/Hose Quick Connect Fitting) .
3. Install the engine oil cooler lines to the engine oil filter adapter. Refer to Engine Oil Cooler
Pipe/Hose Quick Connect Fitting (See: Engine Oil
Cooler Pipe/Hose Quick Connect Fitting) .
4. Install the engine oil cooler line support clip to the engine oil cooler lines. 5. Install the right
engine splash shield. Refer to Engine Splash Shield Replacement (Right) Engine Splash Shield
Replacement (Left) . 6. Install the lower air baffle. Refer to Radiator Air Lower Baffle and Deflector
Replacement (See: Cooling System/Radiator/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4168
7. Add the proper amount of engine oil.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4169
Oil Cooler: Service and Repair Auxiliary Engine Oil Cooler Replacement
Auxiliary Engine Oil Cooler Replacement
Removal Procedure
1. Remove the upper air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement
(See: Cooling System/Radiator/Service and Repair) . 2. Remove the right engine splash shield.
Refer to Engine Splash Shield Replacement (Right) Engine Splash Shield Replacement (Left) . 3.
Remove the lower air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement (See:
Cooling System/Radiator/Service and Repair) . 4. Remove the support clip from the engine oil
cooler lines. 5. Reposition the hose clamps on the power steering cooler lines. 6. Remove the
power steering oil cooler lines from the power steering cooler. 7. Remove the engine oil cooler lines
from the engine oil cooler. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting (See:
Engine Oil
Cooler Pipe/Hose Quick Connect Fitting) .
8. Remove the upper bolt (1) from the engine oil cooler/power steering cooler. 9. Remove the lower
bolts (2) from the engine oil cooler/power steering cooler.
10. Remove the engine oil cooler/power steering cooler from the vehicle.
Installation Procedure
1. Install the engine oil cooler/power steering cooler to the vehicle.
Notice: Refer to Fastener Notice .
2. Install the upper bolt (1) to the engine oil cooler/power steering cooler bracket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 4170
Tighten the bolt to 2 N.m (18 lb in).
3. Install the lower bolts (2) to the engine oil cooler/power steering cooler bracket.
Tighten the bolts to 2 N.m (18 lb in).
4. Install the engine oil cooler lines to the engine oil cooler. Refer to Engine Oil Cooler Pipe/Hose
Quick Connect Fitting (See: Engine Oil Cooler
Pipe/Hose Quick Connect Fitting) .
5. Install the power steering oil cooler lines to the power steering cooler. 6. Reposition the hose
clamps on the power steering cooler lines. 7. Install the support clip to the engine oil cooler lines. 8.
Install the right engine splash shield. Refer to Engine Splash Shield Replacement (Right) Engine
Splash Shield Replacement (Left) . 9. Install the lower air baffle. Refer to Radiator Air Lower Baffle
and Deflector Replacement (See: Cooling System/Radiator/Service and Repair) .
10. Install the upper air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See:
Cooling System/Radiator/Service and Repair) . 11. Add the proper amount of engine oil and power
steering fluid. 12. Bleed the power steering system. Refer to Power Steering System Bleeding .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve
Lifter Tick Noise At Start Up
Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve
Lifter Tick Noise At Start Up > Page 4179
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-01-007C > Feb > 11 >
Engine - Valve Lifter Tick Noise At Start Up
Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-01-007C > Feb > 11 >
Engine - Valve Lifter Tick Noise At Start Up > Page 4185
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-01-016B > Jul > 09 >
Engine - Noise/Damage Oil Filter Application Importance
Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 08-07-30-007B > Jun > 09
> A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 08-07-30-007B > Jun > 09
> A/T - Key Cannot Be Removed/No Shift From Park > Page 4195
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 08-07-30-007B > Jun > 09
> A/T - Key Cannot Be Removed/No Shift From Park > Page 4201
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 4202
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 4203
Notice: Refer to Fastener Notice .
Important: Prior to installing a NEW oil filter, ensure that the old oil filter gasket has been removed
from the engine block. If not, remove the old gasket.
1. Install a NEW engine oil filter (437).
Tighten the filter to 30 N.m (22 lb ft).
2. Install the oil pan drain plug (430) and O-ring (429).
Tighten the drain plug to 25 N.m (18 lb ft).
3. Lower the vehicle. 4. Fill the engine with the appropriate amount and type of NEW engine oil.
Refer to Approximate Fluid Capacities and Fluid and Lubricant
Recommendations .
5. Check the oil level. 6. Install the oil fill cap. 7. Close the hood. 8. Reset the engine oil life monitor,
if necessary. Refer to GM Oil Life System Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair
Oil Filter Adapter: Service and Repair
Oil Filter Adapter Replacement
Removal Procedure
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 4. Remove the oil pan drain plug (430) and O-ring (429). 5. Allow the oil to
drain into an appropriate container.
6. Remove the engine oil filter (437). Allow the rest of the engine oil to drain into an appropriate
container.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair > Page 4207
7. Remove the oil filter adapter (438).
Installation Procedure
Notice: Refer to Fastener Notice .
Important: Prior to installing a NEW oil filter, ensure that the old oil filter gasket has been removed
from the engine block. If not, remove the old gasket.
1. Install a NEW oil filter adapter (438).
Tighten the adapter to 55 N.m (40 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair > Page 4208
2. Install a NEW engine oil filter (437).
Tighten the filter to 30 N.m (22 lb ft).
3. Install the oil pan drain plug (430) and O-ring (429).
Tighten the drain plug to 25 N.m (18 lb ft).
4. Lower the vehicle. 5. Fill the engine with the appropriate amount and type of NEW engine oil.
Refer to Approximate Fluid Capacities and Fluid and Lubricant
Recommendations .
6. Check the oil level. 7. Install the oil fill cap. 8. Close the hood. 9. Reset the engine oil life monitor,
if necessary. Refer to GM Oil Life System Resetting .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Locations
Oil Level Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Locations > Page 4212
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Locations > Page 4213
Oil Level Sensor: Diagrams
Component Connector End Views
Engine Oil Level Switch (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Locations > Page 4214
Oil Level Sensor: Service and Repair
Engine Oil Level Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Drain the oil from the
oil pan. 3. Disconnect the oil level sensor electrical connector.
4. Remove the oil level sensor bolt (751). 5. Remove the oil level sensor (727) and O-ring (728)
from the oil pan.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Locations > Page 4215
1. Install the oil level sensor (727) and O-ring (728) to the oil pan.
Notice: Refer to Fastener Notice .
2. Install the oil level sensor bolt (751).
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the oil level sensor electrical connector. 4. Lower the vehicle. 5. Refill the engine oil to
the proper level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications
Oil Pan: Specifications
Oil Pan M6 Bolts - Oil Pan-to-Rear Housing
........................................................................................................................................... 12 N.m
(106 lb in) Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover
................................................................................................. 25 N.m (18 lb ft)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 4219
Oil Pan: Service and Repair
Oil Pan Replacement
Removal Procedure
1. Remove the engine frame. Refer to Frame Replacement . 2. Drain the engine oil and remove the
engine oil filter. 3. Reinstall the drain plug and oil filter until snug. 4. Remove the transaxle
converter cover bolt/stud and cover.
5. Disconnect the oil level sensor electrical connector. 6. Remove engine harness retainer from the
front of oil pan.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 4220
7. Position the drive belt tensioner aside in order to access the oil pan bolt. Refer to Drive Belt
Tensioner Replacement - Accessory (See: Drive
Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair) .
8. Remove the oil pan bolts. 9. Remove the oil pan.
Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the
openings as required.
10. Drill (3) out the oil pan gasket retaining rivets (2), if required. 11. Remove the gasket (1) from
the pan. 12. Discard the gasket and rivets. 13. Clean and inspect the engine oil pan. Refer to Oil
Pan Cleaning and Inspection (See: Service and Repair/Overhaul) .
Installation Procedure
Important:
* The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide
mounting points for the transmission housing. To ensure the rigidity of the powertrain and correct
transmission alignment, it is important that the rear of the block and the rear of the oil pan are flush,
or even. The rear of the oil pan must NEVER protrude beyond the engine block and transmission
housing plane.
* Do NOT reuse the oil pan gasket.
* It is NOT necessary to rivet the NEW gasket to the oil pan.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 4221
1. Apply a 5 mm (0.20 in) bead of sealant , or equivalent 20 mm (0.80 in) long to the engine block.
Apply the sealant directly onto the tabs of the
front/rear cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids,
Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the
correct part number.
Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the
oil pan gasket.
2. Pre-assemble the oil pan gasket to the pan.
1. Install the gasket onto the pan. 2. Install the oil pan bolts to the pan and through the gasket.
Notice: Refer to Fastener Notice .
3. Install the oil pan, gasket, and bolts to the engine block.
* Tighten the oil pan and oil pan-to-front cover bolts to 25 N.m (18 lb ft).
* Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in).
* Tighten the transmission housing, converter cover, and transmission bolts/stud to 50 N.m (37 lb
ft).
4. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory (See:
Drive Belts, Mounts, Brackets and
Accessories/Drive Belt Tensioner/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 4222
5. Install engine harness to front of oil pan. 6. Connect the oil level sensor electrical connector.
7. Install the transaxle converter cover and bolt/stud.
Tighten the bolt/stud to 12 N.m (106 lb in).
8. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement (See:
Engine Oil/Service and Repair) . 9. Install the engine frame. Refer to Frame Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Locations
Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Locations > Page 4226
15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Locations > Page 4227
Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Locations > Page 4228
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Intake Manifold/Service and Repair)
.
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Locations > Page 4229
1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Specifications/Adhesives, Fluids,
Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and
Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure - Minimum Hot
1,000 engine RPM ...............................................................................................................................
....................................................... 6 psig (41 kPa) 2,000 engine RPM ..............................................
.................................................................................................................................... 18 psig (124
kPa) 4,000 engine RPM ......................................................................................................................
............................................................ 24 psig (165 kPa)
Active Fuel Management Relief Valve - RPO LC9, LMG, LH6, L76
Oil Pressure .........................................................................................................................................
...................... 55-75 psig (379-517 kPa) Min-Max.
NOTE: As Measured at Oil Pressure Sensor Location.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications > Page 4234
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant In Engine Oil) .
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
following conditions:
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul) .
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul) .
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul) .
* Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder
Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See:
Testing and Inspection/Component Tests and General Diagnostics) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement
Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement
INFORMATION
Bulletin No.: 00-06-01-026C
Date: February 03, 2010
Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to include additional model years. Please discard
Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine).
When replacing an engine due to internal damage, extreme care should be taken when transferring
the intake manifold to the new Goodwrench service engine long block. Internal damage may result
in the potential discharge of internal engine component debris in the intake manifold via broken
pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the
engine, the technician should carefully inspect all of the cylinder head intake ports to see if the
valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently
bent, internal engine component debris will be present to varying degrees in the intake port of the
cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold
should be replaced. This replacement is required due to the complex inlet runner and plenum
configuration of most of the intake manifolds, making thorough and complete component cleaning
difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake
manifold removed from an engine with deposits of internal engine component debris may result in
the ingestion of any remaining debris into the new Goodwrench service engine. This may cause
damage or potential failure of the new service engine.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Page 4239
Intake Manifold: Specifications
Intake Manifold Bolts - First Pass in Sequence
............................................................................................................................................ 5 N.m (44
lb in) Intake Manifold Bolts - Final Pass in Sequence
......................................................................................................................................... 10 N.m (89
lb in)
Throttle Body Bolts ..............................................................................................................................
...................................................... 10 N.m (89 lb in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement
Intake Manifold: Service and Repair Intake Manifold Replacement
Intake Manifold Replacement
Removal Procedure
Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an
assembly. If not servicing the individual components, remove the manifold as a complete
assembly.
1. Remove the throttle body. Refer to Throttle Body Assembly Replacement . 2. Remove the fuel
injectors. Refer to Fuel Injector Replacement . 3. Remove the brake booster vacuum hose (1) from
the intake manifold (2) and the booster check valve (3).
4. Remove the positive crankcase ventilation (PCV) clean air tube from the air intake duct and
valve rocker arm cover. Refer to Plastic Collar Quick
Connect Fitting Service .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4242
5. Remove the PCV foul air tube from the intake manifold and valve rocker arm cover. Refer to
Plastic Collar Quick Connect Fitting Service .
6. Remove the evaporative emission (EVAP) purge solenoid tube (2) from the solenoid and
reposition. Refer to Plastic Collar Quick Connect Fitting
Service .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4243
7. Disconnect the following electrical connectors:
* EVAP purge solenoid (1)
* Manifold absolute pressure (MAP) sensor (2)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)
8. Remove the MAP sensor (714) from the intake manifold.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4244
9. Remove the EVAP purge solenoid valve and bracket.
10. Remove the intake manifold bolts (512). 11. Remove the intake manifold (500).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4245
12. Remove and discard the intake manifold gaskets (514).
Installation Procedure
1. Install the NEW intake manifold gaskets (514).
2. Install the intake manifold (500). 3. Apply a band of threadlock to the threads of the intake
manifold bolts (512).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4246
Notice: Refer to Fastener Notice .
4. Install the intake manifold bolts.
* Tighten the bolts a first pass in sequence to 5 N.m (44 lb in).
* Tighten the bolts a first pass in sequence to 10 N.m (89 lb in).
5. Install the EVAP purge solenoid bracket and solenoid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4247
6. Install the MAP sensor (714) to the intake manifold.
7. Connect the following electrical connectors:
* EVAP purge solenoid (1)
* MAP sensor (2)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)
8. Position and install the EVAP purge solenoid tube (2) to the solenoid. Refer to Plastic Collar
Quick Connect Fitting Service .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4248
9. Install the PCV foul air tube to the intake manifold and valve rocker arm cover. Refer to Plastic
Collar Quick Connect Fitting Service .
10. Install the PCV clean air tube to the air intake duct and valve rocker arm cover. Refer to Plastic
Collar Quick Connect Fitting Service .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4249
11. Install the brake booster vacuum hose (1) to the intake manifold (2) and the booster check
valve (3). 12. Install the fuel injectors. Refer to Fuel Injector Replacement . 13. Install the throttle
body. Refer to Throttle Body Assembly Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Intake Manifold Replacement > Page 4250
Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement
Upper Intake Manifold Sight Shield Replacement
Removal Procedure
1. Pull up on the front and rear of the sight shield in order to disengage sight shield from the studs.
2. Remove the engine sight shield from the vehicle.
Installation Procedure
Important: When installing the engine sight shield, ensure the heater hoses sit on top of the shield
to prevent wear over time.
1. Align the sight shield to the studs on the intake manifold. 2. Push down in the 3 locations in order
to secure the sight shield to the studs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Oil Seal Replacement
Special Tools
* J 41479 Crankshaft Rear Oil Seal Installer
* J 41479-2A Crankshaft Rear Oil Seal Installation Guide
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) . 2. Remove and discard the crankshaft rear oil seal
(141).
Installation Procedure
Important: For proper orientation, note the installation direction of the oil seal. The oil seal is a
reverse-lip design. The part number is applied to the outside face of the seal, as shown.
1. Inspect the seal and identify the part number markings for proper orientation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair > Page 4255
Important: *
Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface.
* Do not reuse the crankshaft rear oil seal.
2. Lubricate the outside diameter (OD) of the oil seal (141) with clean engine oil. DO NOT allow oil
or other lubricants to contact the seal surface. 3. Lubricate the rear cover oil seal bore with clean
engine oil. DO NOT allow oil or other lubricants to contact the crankshaft surface.
4. Install the J 41479 tapered cone (2) with the J 41479-2A and bolts onto the rear of the
crankshaft. 5. Tighten the bolts until snug. Do not overtighten. 6. Install the rear oil seal onto the
tapered cone (2) and push the seal to the rear cover bore. 7. Install the oil seal with the part
number markings facing away from the engine. 8. Thread the J 41479 threaded rod into the
tapered cone until the tool (1) contacts the oil seal. 9. Align the oil seal into the tool (1).
10. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into
the cover bore. 11. Remove the J 41479 and the J 41479-2A . 12. Install the engine flywheel. Refer
to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair)
.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal Replacement
Tools Required
J 41478 Crankshaft Front Oil Seal Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
2. Remove and discard the crankshaft oil seal (140).
Installation Procedure
Important:
* Do not lubricate the oil seal sealing surface.
* Do not reuse the crankshaft oil seal.
1. Lubricate the outer edge of the oil seal (140) with clean engine oil. 2. Lubricate the front cover oil
seal bore with clean engine oil.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair > Page 4259
3. Install the crankshaft front oil seal (140) onto the J 41478 . 4. Install the J 41478 threaded rod
with nut, washer, guide, and oil seal into the end of the crankshaft. 5. Using the J 41478 , install the
oil seal into the cover bore.
1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the
installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect
the oil seal for proper installation. The oil seal should be installed evenly and completely into the
front cover bore.
6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Tools Required
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair) .
Important: Remove the spark plugs from the cylinder head with the engine at room temperature.
2. Loosen the spark plug 1 or 2 turns. 3. Brush or air blast away any dirt or debris from around the
spark plug. 4. Remove the spark plug.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 4263
5. Install the J 22794 into the spark plug hole. 6. Attach an air hose to the J 22794 . 7. Apply
compressed air to the J 22794 in order to hold the valves in place.
8. Using the J 38606 compress the valve spring.
9. Remove the valve stem keys (225).
10. Using the J 38606 carefully release the valve spring tension. 11. Remove the J 38606 . 12.
Remove the valve spring cap (224).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 4264
13. Remove the valve spring (223). 14. Remove the valve stem oil seal (222) .
Installation Procedure
1. Clean the cylinder head valve spring seat and area. 2. Install the valve stem oil seal (222). 3.
Install the valve spring (223). 4. Install the valve spring cap (224).
5. Compress the valve spring using the J 38606 . 6. Install the valve stem keys.
1. Use grease in order to hold the valve stem keys in place. 2. Make sure the keys seat properly in
the groove of the valve stem. 3. Using the J 38606 carefully release the valve spring tension,
making sure the valve stem keys stay in place. 4. Remove the J 38606 . 5. Tap the end of the valve
stem with a plastic faced hammer to seat the keys, if necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 4265
7. Remove the compressed air supply from the J 22794 . 8. Remove the J 22794 from the spark
plug port.
Notice: Refer to Fastener Notice .
9. Hand start the spark plug.
Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level
Sensor > Component Information > Locations
Oil Level Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level
Sensor > Component Information > Locations > Page 4270
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level
Sensor > Component Information > Locations > Page 4271
Oil Level Sensor: Diagrams
Component Connector End Views
Engine Oil Level Switch (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level
Sensor > Component Information > Locations > Page 4272
Oil Level Sensor: Service and Repair
Engine Oil Level Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Drain the oil from the
oil pan. 3. Disconnect the oil level sensor electrical connector.
4. Remove the oil level sensor bolt (751). 5. Remove the oil level sensor (727) and O-ring (728)
from the oil pan.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level
Sensor > Component Information > Locations > Page 4273
1. Install the oil level sensor (727) and O-ring (728) to the oil pan.
Notice: Refer to Fastener Notice .
2. Install the oil level sensor bolt (751).
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the oil level sensor electrical connector. 4. Lower the vehicle. 5. Refill the engine oil to
the proper level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Locations
Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Locations > Page 4277
15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Locations > Page 4278
Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Locations > Page 4279
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Intake Manifold/Service and Repair)
.
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Locations > Page 4280
1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Specifications/Adhesives, Fluids,
Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and
Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt - 1-Bolt Sprocket - First Pass
............................................................................................................................... 75 N.m (55 lb ft)
Camshaft Sprocket Bolt - 1-Bolt Sprocket - Final Pass
........................................................................................................................................ 50 degrees
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Timing Chain and Sprocket Replacement
Tools Required
* J 8433 Two Jaw Puller
* J 41816-2 Crankshaft End Protector
* J 41558 Crankshaft Sprocket Remover
* J 41665 Crankshaft Balancer and Sprocket Installer
Removal Procedure
Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to
prevent damage to the piston assemblies or the valves.
1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement
(See: Engine Lubrication/Oil Pump/Service and
Repair) .
2. Remove and discard the camshaft sprocket bolt (206). 3. Remove the camshaft sprocket (205)
and timing chain (208).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4288
4. Remove the bolts (231) and timing chain tensioner (232).
5. Use the J 41816-2 (1), the J 41558 (2), bolts (3), and the J 8433 (4) in order to remove the
crankshaft sprocket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4289
6. Remove the crankshaft sprocket (207).
7. Remove the crankshaft sprocket key, as required.
Installation Procedure
1. Install the key into the crankshaft keyway, if previously removed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4290
2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key
with the crankshaft sprocket keyway.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4291
4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket.
Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
6. Compress the timing chain tensioner guide and install the EN 46330 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4292
Notice: Refer to Fastener Notice .
7. Install the timing chain tensioner (232) and bolts (231).
Tighten the timing chain tensioner bolts to 25 N.m (18 lb ft).
Important: *
Do not use the camshaft sprocket bolt again. Install a NEW bolt during assembly.
* The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
8. Install the camshaft sprocket (205), timing chain (208), and NEW bolt (206).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4293
9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the
crankshaft sprocket (2) should be located in the 12 o'clock position.
10. Remove the EN 46330 .
Important: Do not apply threadlock to the flex plate bolts at this time.
11. Temporarily install the automatic transmission flex plate and bolts. Refer to Engine Flywheel
Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4294
12. Install the EN 47699 (2), spacer (1), and bolts (3) to the block and flex plate.
13. Tighten the EN 47699 bolt (1).
Tighten the bolt to 60 N.m (44 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 4295
14. Tighten the camshaft sprocket bolt.
1. Tighten the camshaft sprocket bolt a first pass to 75 N.m (55 lb ft). 2. Tighten the camshaft
sprocket bolt a final pass an additional 50 degrees using the J 45059 .
15. Remove the J 42386-A and bolts. 16. Remove the automatic transmission flex plate and bolt.
Refer to Engine Flywheel Removal (See: Service and Repair/Overhaul) . 17. Install the oil pump.
Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil
Pump/Service and
Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioner Bolts .............................................................................................................
....................................................... 25 N.m (18 lb ft)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component
Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
^ Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be
located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in
the 12 o'clock position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Front Cover Bolts .................................................................................................................................
....................................................... 25 N.m (18 lb ft)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 4305
Timing Cover: Service and Repair
Engine Front Cover Replacement
Tools Required
J 41476 Front and Rear Cover Alignment Tool (at crankshaft seal area)
Removal Procedure
1. Remove the generator. Refer to Generator Replacement (LS4) Generator Replacement (RPOs
LZE/LZ4/LZ8) . 2. Remove the power steering pump. Refer to Power Steering Pump Replacement
(LZ4/LZE/LZ9) Power Steering Pump Replacement (LS4) . 3. Remove the coolant pump manifold.
Refer to Coolant Pump Manifold Replacement (See: Water Pump/Service and Repair) . 4. Remove
the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
5. Remove the belt tensioner bolt and reposition the tensioner (which blocks the front cover bolt). 6.
Remove the oil pan-to-front cover bolts. 7. Remove the front cover bolts (1). 8. Remove the front
cover (2) and gasket (3). 9. Discard the front cover gasket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 4306
10. Remove the oil seal (4). 11. Remove the bolt (1) and camshaft position (CMP) sensor (2). 12.
Remove the O-ring (3) from the sensor, as required.
Installation Procedure
Important:
* Do not reuse the crankshaft oil seal or front cover gasket.
*
Do not apply any type of sealant to the front cover gasket (unless specified).
* The special tool in this procedure is used to properly center the front crankshaft front oil seal.
- All gasket surfaces should be free of oil or other foreign material during assembly.
- The crankshaft front oil seal MUST be centered in relation to the crankshaft.
- An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 4307
1. Install the front cover gasket (3), front cover (2), and bolts (1). 2. Tighten the cover bolts finger
tight. Do not overtighten.
Notice: Refer to Fastener Notice .
Important: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.
3. Install the J 41480 .
Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
Important: Align the tapered legs of the tool with the machined alignment surfaces on the front
cover.
4. Install the J 41476 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 4308
5. Install the crankshaft balancer bolt.
1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. 2. Tighten the J
41480 . 3. Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Remove the tools.
7. Measure the oil pan surface flatness, front cover-to-engine block.
1. Place a straight edge across the engine block and front cover oil pan sealing surfaces.
Avoid contact with the portion of the gasket that protrudes into the oil pan surface.
2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush
with the oil pan surface, or no greater than 0.5
mm (0.02 in) below flush.
8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the
cover alignment procedure. 9. If the correct front cover-to-engine block alignment cannot be
obtained, replace the front cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 4309
10. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not
cut or damaged, it may be used again. 11. Lubricate the O-ring seal with clean engine oil. 12.
Install the O-ring seal onto the sensor (2). 13. Install the sensor to the cover. 14. Install the bolt (1).
Tighten the bolt to 12 N.m (106 lb in).
15. Install the coolant pump manifold. Refer to Coolant Pump Manifold Replacement (See: Water
Pump/Service and Repair) . 16. Inspect the CMP sensor O-ring seal (3) for cuts or damage. If the
seal is not cut or damaged, it may be reused. 17. Lubricate the O-ring seal with clean engine oil.
18. Install the O-ring seal (3) onto the CMP sensor. 19. Install the CMP sensor (2) and bolt (1) from
the front cover.
Tighten the bolt to 12 N.m (106 lb in).
20. Position the belt tensioner and install the bolt.
Tighten the bolt to 50 N.m (37 lb ft).
21. Install the power steering pump. Refer to Power Steering Pump Replacement (LZ4/LZE/LZ9)
Power Steering Pump Replacement (LS4) . 22. Install the generator. Refer to Generator
Replacement (LS4) Generator Replacement (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)..................................................................................................
..............................................345-414 kPa (50-60 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Service Precautions > Technician Safety Information > Page 4316
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4319
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4320
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the fuel pump relay when the ignition switch is turned ON. The control
module will disable the fuel pump relay within 2 seconds unless the control module detects ignition
reference pulses. The control module continues to enable the fuel pump relay as long as ignition
reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if
ignition reference pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
*
Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Component
Tests and General Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa
(50-60 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 4321
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel
rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF
with a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the fuel pump module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Powertrain Management/Computers and Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine
Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Assembly Replacement
* Fuel Injector Replacement
* Fuel Tank Fuel Pump Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Not supplied by manufacturer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Disconnect the positive crankcase ventilation (PCV) tube from the air inlet duct.
2. Loosen the air inlet duct clamp at the throttle body. 3. Remove the air inlet duct from the throttle
body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4329
4. Loosen the air inlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5.
Remove the air inlet duct from the MAF/IAT sensor.
Installation Procedure
1. Install the air inlet duct from the MAF/IAT sensor.
Notice: Refer to Fastener Notice.
2. Tighten the air inlet duct clamp at the MAF/IAT sensor.
Tighten the clamp to 3 N.m (27 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4330
3. Install the air inlet duct to the throttle body. 4. Tighten the air inlet duct clamp at the throttle body.
Tighten the clamp to 3 N.m (27 lb in).
5. Connect the PCV tube to the air inlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. 2. Release the spring clamps on top of the air cleaner
housing. 3. Remove the air cleaner housing cover. 4. Remove the air filter element.
Installation Procedure
1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Engage the spring
clamps on top of the air cleaner housing. 4. Install the air cleaner outlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 4339
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 4340
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 4341
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
...........................................................1-8-7-2-6-5-4-3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
...........................................................397-1,337 ohms
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications > Page 4348
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
following conditions:
1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications > Page 4349
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the spark plug.
2. Remove the spark plug wire from the ignition coil (724).
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil (724). 2. Install the spark plug wire to the spark plug.
3. Inspect the spark plug wire for proper installation:
1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.......................................................1.02 mm - 0.040 in Spark Plug Torque..........................................
................................................................................................................................................15 N.m 11 lb ft
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications > Page 4353
Spark Plug: Application and ID
Spark Plug
Type..........................................................................................................................................GM
P/N 12571164 (AC Spark Plug P/N 41-985)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications > Page 4354
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - colder plug
- Pre-ignition causing spark plug and/or engine damage - hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications > Page 4355
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively-wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over-torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes reduce or eliminates the gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications > Page 4356
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot
engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug
thread damage or cylinder head damage.
1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using
compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Specifications > Page 4357
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed.
Spark plug gap: 1.016 mm (0.040 in).
3. Hand start the spark plug in the corresponding cylinder.
Notice: Refer to Fastener Notice.
4. Tighten the spark plug.
Tighten the plug to 15 N.m (11 lb ft).
5. Install the spark plug wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa (100 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 4361
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Bolts ................................................................................................................................
...................................................... 10 N.m (89 lb in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement
Water Pump: Service and Repair Coolant Pump Manifold Replacement
Coolant Pump Manifold Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Cooling
System/Service and Repair)Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill) (See:
Cooling System/Service and Repair) .
2. Loosen the water pump bolts (318). 3. Remove the drive belt. Refer to Drive Belt Replacement Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and
Repair) .
4. Remove fluid from the power steering pump reservoir. 5. Remove the power steering pump
pulley. Refer to Power Steering Pump Pulley Replacement (LZ4/LZE/LZ9) Power Steering Pump
Pulley
Replacement (LS4) .
6. Disconnect the power steering hoses and pipes from the power steering pump and reservoir.
Refer to Power Steering Cooler Pipe/Hose
Replacement (3.5L and 3.9L) Power Steering Cooler Pipe/Hose Replacement (LS4) and Power
Steering Pressure Pipe/Hose Replacement (LZ4/LZE/LZ9) Power Steering Pressure Pipe/Hose
Replacement (LS4) .
7. Remove the bolt that retains a clip that retains the pressure pipe to the front of the engine. 8.
Remove the water pump bolts (318). 9. Remove the water pump (300) and gasket (314). Discard
the gasket.
10. Remove the camshaft position sensor. Refer to Camshaft Position Sensor Replacement . 11.
Unclip the wiring harness from the front of the engine.
12. Disconnect the engine coolant air bleed pipe hoses and clamps. Refer to Engine Coolant Air
Bleed Hose Replacement (LS4) (See: Cooling
System/Coolant Line/Hose/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement > Page 4367
13. Remove the three coolant pump manifold to cylinder head bolts. 14. Disconnect the heater
hoses at the coolant pump manifold. Refer to Heater Pipes Replacement (LS4) Heater Pipes
Replacement (LZE, LZ4, LZG)
.
15. Disconnect the radiator hoses from the coolant pump manifold. Refer to Radiator Inlet Hose
Replacement (RPO LS4) (See: Cooling
System/Radiator Hose/Service and Repair).
16. Remove the coolant pump manifold bolts (301). 17. Remove the coolant pump manifold (315)
and gaskets (306). Discard the gaskets. 18. Clean and inspect the water pump manifold mounting
surfaces.
19. Remove the thermostat housing bolts (302), if necessary. 20. Remove the thermostat housing
(303) and O-ring seal (304), if necessary. 21. Remove the thermostat (305), if necessary. 22.
Remove the power steering pump and reservoir from the coolant pump manifold. 23. Remove the
drive belt idler pulleys from the coolant pump manifold.
Installation Procedure
Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling system or the engine components/assembly.
Important: All gasket surfaces are to be free of oil and other foreign material during assembly.
1. Install the drive belt idler pulleys to the coolant pump manifold. Refer to Drive Belt Idler Pulley
Replacement (See: Drive Belts, Mounts,
Brackets and Accessories/Idler Pulley/Service and Repair) .
2. Install the power steering pump and reservoir to the coolant pump manifold. Refer to Power
Steering Pump Replacement (LZ4/LZE/LZ9) Power
Steering Pump Replacement (LS4) and Remote Power Steering Fluid Reservoir Replacement .
3. Install the thermostat (305), if necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement > Page 4368
4. Install the thermostat housing (303) and O-ring seal (304), if necessary.
Notice: Refer to Fastener Notice .
5. Install the thermostat housing bolts (302), if necessary.
Tighten the bolts to 15 N.m (11 lb ft).
6. Install the water pump manifold (315) and NEW gaskets (306).
1. Tighten the M10 bolts to 60 N.m (44 lb ft). 2. Tighten the M8 bolts to 30 N.m (22 lb ft).
7. Install the water pump manifold bolts (301). 8. Install the camshaft position sensor. Refer to
Camshaft Position Sensor Replacement . 9. Install the cylinder head to coolant pump manifold
bolts.
10. Connect the engine coolant air bleed pipe hose and clamp.
11. Install the water pump (300) and a NEW gasket (314). 12. Install the water pump bolts (318)
until sung. 13. Connect the power steering pipes and hoses to the pump and reservoir. Refer to
Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Power Steering Cooler Pipe/Hose Replacement (LS4) and Power Steering Pressure Pipe/Hose
Replacement (LZ4/LZE/LZ9) Power Steering Pressure Pipe/Hose Replacement (LS4) .
14. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement
(LZ4/LZE/LZ9) Power Steering Pump Pulley
Replacement (LS4) .
15. Install the bolt that retains the power steering pipe to the front of the engine. 16. Install the
wiring harness to the clips on the front of the engine. 17. Install the drive belt. Refer to Drive Belt
Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service
and
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement > Page 4369
Repair) .
18. Tighten the water pump bolts (318).
Tighten the bolts to 10 N.m (89 lb in).
19. Connect the heater hoses to the coolant pump manifold. Refer to Heater Pipes Replacement
(LS4) Heater Pipes Replacement (LZE, LZ4, LZG) . 20. Connect the radiator hoses to the coolant
pump manifold. Refer to Radiator Inlet Hose Replacement. See: Cooling System/Radiator
Hose/Service
and Repair
21. Fill and bleed the power steering system. Refer to Checking and Adding Power Steering Fluid
and Power Steering System Bleeding . 22. Fill the cooling system. Refer to Cooling System
Draining and Filling (9C1, 9C3 Static Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Cooling
System/Service and Repair)Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill) (See:
Cooling System/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement > Page 4370
Water Pump: Service and Repair Water Pump Replacement
Water Pump Replacement (LS4) (5.3L)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining
and Filling (LZE, LZ4, LZG, Static Fill) .
2. Remove the battery and battery tray. Refer to Battery Tray Replacement (LS4) Battery Tray
Replacement (RPOs LZE/LZ4/LZ8) . 3. Remove the drive belt. Refer to Drive Belt Replacement Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and
Repair) .
4. Remove the water pump bolts (318). 5. Remove the water pump (300) and gasket (314). Discard
the gasket. 6. Clean and inspect the water pump gasket mating surfaces.
Installation Procedure
1. Install the water pump (300) and a NEW gasket (314).
Notice: Refer to Fastener Notice .
2. Tighten the water pump bolts (318).
Tighten the bolts to 10 N.m (89 lb in).
3. Install the drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts,
Brackets and Accessories/Drive Belt/Service and
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service
and Repair > Coolant Pump Manifold Replacement > Page 4371
Repair) .
4. Install the battery tray and battery. Refer to Battery Tray Replacement (LS4) Battery Tray
Replacement (RPOs LZE/LZ4/LZ8) . 5. Fill the cooling system. Refer to Cooling System Draining
and Filling (9C1, 9C3 Static Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining
and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair
Cooling System Air Bleeder Pipe / Hose: Service and Repair
Coolant Air Bleed Pipe Assembly Replacement
Removal Procedure
Important: Removal of the intake manifold is NOT required to service the coolant air bleed pipe, but
is required to service the coolant air bleed pipe covers and/or gaskets.
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Service and Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, Static Fill) (See: Service and Repair) .
2. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Engine/Intake
Manifold/Service and Repair) . 3. Disconnect the hose clamp and hose from the coolant fill neck. 4.
Remove the coolant air bleed pipe bolts (309). 5. Remove the coolant air bleed pipe (307) with
hose and seals (308).
6. Remove the hose (311) and clamps (322) from the coolant air bleed pipe (307) as required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair > Page 4376
7. Remove the engine coolant air bleed cover bolts (312). 8. Remove the covers (313) with seals
(308).
9. Remove the seals (308) from the pipe and covers. Discard the seals.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair > Page 4377
Important: Position the O-ring seal onto the nipple portion of the pipe.
1. Install NEW seals (308) onto the engine coolant air bleed pipe and covers.
2. Install the covers (313) with seals (308).
Notice: Refer to Fastener Notice .
3. Install the engine coolant air bleed cover bolts (312).
Tighten the bolts to 12 N.m (106 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair > Page 4378
4. Install the hose (311) and clamps (322) to the coolant air bleed pipe (307) as required.
5. Install the coolant air bleed pipe (307) with hose and seals (308). 6. Install the coolant air bleed
pipe bolts (309).
Tighten the bolts to 12 N.m (106 lb in).
7. Install the intake manifold. Refer to Intake Manifold Replacement (See: Engine/Intake
Manifold/Service and Repair) . 8. Connect the clamp and hose to coolant fill neck. 9. Fill the cooling
system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Service and
Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, Static Fill) (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Bulletin No.: 05-06-02-002B
Date: January 18, 2008
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Number 05-06-02-002A (Section 06 - Engine/Propulsion System).
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Cooling System Including Reservoir
................................................................................................................................................ 13.3
quarts (12.6 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 4385
Coolant: Fluid Type Specifications
ENGINE COOLANT
The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is
designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs
first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will:
^ Give freezing protection down to -34°F (-37°C).
^ Give boiling protection up to 265°F (129°C).
^ Protect against rust and corrosion.
^ Help keep the proper engine temperature.
^ Let the warning lights and gages work as they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE
Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't
damage aluminum parts. If you use this coolant mixture, you don't need to add anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair
Coolant Line/Hose: Service and Repair
Engine Coolant Air Bleed Hose Replacement (LS4) (5.3L)
Removal Procedure
1. Drain a small amount of coolant from the radiator. Refer to Cooling System Draining and Filling
(9C1, 9C3 Static Fill) (See: Service and Repair
)Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System
Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Reposition the coolant air bleed hose clamp (322) at the coolant air bleed pipe (307). 3.
Reposition the coolant air bleed hose clamp (322) at the water manifold. 4. Remove the coolant air
bleed hose from the water manifold. 5. Remove the coolant air bleed hose from the coolant air
bleed pipe. 6. Remove the clamps from the coolant air bleed hose, if necessary.
Installation Procedure
1. Install the clamps onto the coolant air bleed hose, if necessary. 2. Install the coolant air bleed
hose onto the coolant air bleed pipe. 3. Install the coolant air bleed hose onto the water manifold. 4.
Position the coolant air bleed hose clamp (322) at the water manifold. 5. Position the coolant air
bleed hose clamp (322) at the coolant air bleed pipe (307). 6. Refill the coolant system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Service and Repair)Cooling
System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE,
LZ4, LZG, Static Fill) , as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair
Coolant Reservoir: Service and Repair
Coolant Recovery Reservoir Replacement (LS4) (5.3L)
Removal Procedure
1. Remove the front fender upper diagonal brace. Refer to Front Fender Upper Diagonal Brace
Replacement .
2. Reposition the coolant recovery reservoir hose clamp aside at the radiator overflow fitting. 3.
Disconnect the coolant recovery reservoir hose from the radiator overflow hose. 4. Remove the
coolant recovery reservoir nuts from the shock tower studs. 5. Remove the coolant recovery
reservoir from the lower retainer and the shock tower studs. 6. Drain the coolant from the coolant
recovery reservoir into a clean container.
Installation Procedure
1. Install the coolant recovery reservoir to the lower retainer and the shock tower studs.
Notice: Refer to Fastener Notice .
2. Install the nuts to the shock tower studs.
Tighten the nuts to 3.3 N.m (29 lb in).
3. Lubricate the reservoir hose with clean water. Install the coolant reservoir hose to the radiator
overflow hose. 4. Position the coolant reservoir hose clamp to the radiator overflow hose fitting. 5.
Install the front fender upper diagonal brace. Refer to Front Fender Upper Diagonal Brace
Replacement . 6. Fill the coolant recovery reservoir to the proper level. Refer to Cooling System
Draining and Filling (9C1, 9C3 Static Fill) (See: Service and
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Page 4392
Repair)Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4398
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4399
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4400
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4401
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4402
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4403
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4404
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4405
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4406
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4407
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4408
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4409
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4410
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4411
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4412
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4413
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4415
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4416
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4417
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4418
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426
Radiator Cooling Fan Motor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4471
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4476
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4485
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4519
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4520
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4521
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4522
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4523
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4524
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 4525
Radiator Cooling Fan Motor: Service and Repair
Engine Coolant Fan Motor Replacement
Tools Required
GE-47827 Socket
Removal Procedure
Caution: An electric fan under the hood can start up even when the engine is not running and can
injure you. Keep hands, clothing and tools away from any underhood electric fan.
Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan
blade or housing should always be replaced.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment
come in contact with an exposed electrical terminal. Failure to follow these precautions may result
in personal injury and/or damage to the vehicle or its components.
1. Remove the fan shroud assembly from the vehicle. Refer to Fan Shroud Replacement (See: Fan
Shroud/Service and Repair) .
Important: Hold the fan blade to prevent rotation.
2. Using GE-47827 turn the fan motor drive plate in the opposite direction of the arrow on the fan
blade until the motor drive plate disengages from
the fan blade.
3. Remove and discard the fan blade.
Notice: Failure to tape off all of the entry points to the cooling fan motor(s) will allow debris to enter
and damage the motor(s).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 4526
Important: When reusing the fan motor tape off the front and rear entry points of the fan motor
before drilling the rivets.
4. Center punch each of the rivets (1) from the rear of the motor. 5. Drill the head of the rivets (1)
from the fan motor using a 6.35 mm (0.25 in) drill bit.
6. Tap the rivets out of the fan shroud.
7. Remove the fan motor from the fan shroud.
Important: Blow off any excess debris from the fan motor.
8. Remove the tape covering the entry points from the fan motor.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 4527
1. Install the engine cooling fan motor to the fan shroud.
Important: Position the fan motor to the fan shroud and insert the bolts from the front side.
2. Install the cooling fan motor bolts.
Notice: Refer to Fastener Notice .
3. Install the cooling fan motor nuts.
Tighten the nuts to 6 N.m (53 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 4528
Notice: Failure to heat the fan hub in hot tap water before installation will result in cooling fan failure
due to cracking. Allowing the heated fan to cool for more than one minute prior to installation will
also result in failure due to cracking.
Important: Using hot tap water at a minimum of 49°C (120°F), hold the new fan blade hub under
the running water for a minimum of 60 seconds to heat the fan blade to the temperature of the
water.
Immediately after heating, position the fan blade on the fan motor drive plate.
4. Install the new engine cooling fan blade.
Important: Hold the fan blade to prevent rotation.
5. Using the GE-47827 turn the fan motor drive plate in the same direction of the arrow on the fan
blade until the fan motor drive plate engages to
the fan blade. Full engagement is attained when the motor drive plate fully occupies the three slots
in the face of the fan blade.
6. Rotate the cooling fan blade to ensure proper rotation. 7. Install the fan shroud assembly to the
vehicle. Refer to Fan Shroud Replacement (See: Fan Shroud/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set
Technical Service Bulletin # 09-06-03-007 Date: 090827
Cooling System - MIL ON DTC P0480/P0481 Set
TECHNICAL
Bulletin No.: 09-06-03-007
Date: August 27, 2009
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTC P0480 and/or P0481 Set Temperature Gage Indicates Hot - Cooling Fans Intermittent or Inoperative (Install Revised Cooling
Fan Relay and Harness Assembly)
Models:
2006-2009 Chevrolet Impala Police Sedan (RPO 9C1 Only) 2010 Chevrolet Impala Police Sedan
(with RPO 9C1 and without RPO WRH)
Condition
Some customers may comment that the instrument panel temperature gage indicates hot.
Some customers may also comment that the malfunction indicator lamp (MIL) is illuminated.
The technician may observe that DTC P0480 and/or P0481 are set as current or in history and/or
the engine cooling fans are intermittent or inoperative.
Cause
This condition may be caused by high underhood bussed electrical center (UBEC) temperatures
which may result in the cooling fans becoming intermittent or inoperative under certain operating
conditions.
Disclaimer
Part # 1
A revised engine cooling fan relay and harness assembly has been released, to reposition the
cooling fan relays for increased air circulation.
1. Turn OFF the ignition, all electrical components, lamps, accessories and the scan tool.
Open the hood.
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4537
2. Remove the RH front fender upper diagonal brace bolts (1). Release the retainer that secures
the wiring harness from the bottom of the brace (2),
then remove the upper diagonal brace.
3. Loosen the negative battery cable terminal nut and remove the battery cable terminal from the
battery. Refer to Battery Negative Cable
Disconnection and Connection in SI.
4. Open the positive battery cable terminal cover, loosen the battery cable terminal nut and remove
the battery cable terminal from the battery.
5. Remove the battery insulator.
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4538
6. Remove the battery hold down bolt and the hold down.
Note Do not tip the battery more than 40 degrees during removal.
7. Remove the battery. 8. Release the inner RH headlamp retainer by pulling the retainer upward.
9. Remove the RH headlamp assembly bolt.
10. Pull the headlamp from the outboard edge in order to release the lock pin from the fender
flange retainer. 11. Disconnect the electrical connector before removing the headlamp from the
vehicle.
12. Remove the fuse block underhood electrical center cover (1).
Note Observe the positions and orientations of the forward lamp battery supply harness terminal
and the fusible links on the studs before removing.
13. At the top of the fuse block disconnect the two fasteners on the fuse block battery studs and
remove the forward lamp battery supply harness
terminal and the fusible links. Remove the fasteners (1) securing the electrical center board (2).
14. Unlock the tabs on the electrical center board, then evenly lift up on the board in order to
remove it.
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4539
15. In the illustration above observe the orientation of the schematic for the fuse block. Identify the
location of connectors X1 and X3.
16. Locate and mark for reference, the following circuit terminals:
- Connector X1, Circuit 473, 0.35 D-BU, Pin C7, High Speed Cooling Fan Relay Control
- Connector X1, Circuit 335, 0.35 D-GN, Pin H7, Low Speed Cooling Fan Relay Control
17. Locate and mark for reference, the following circuit terminals:
- Connector X3, Circuit 409, 3 L-BU, Pin D1, Cooling Fan - Right Supply Voltage
- Connector X3, Circuit 532, 3 GY, Pin E1, Cooling Fan - Left Low Reference
- Connector X3, Circuit 504, 3 WH, Pin F2, Cooling Fan - Left Supply Voltage
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4540
18. Remove both fuse block engine harness connectors X1 (1) and X3 (2) from their respective
cavities.
1. Release and remove the bottom cover on both connectors.
2. Examine the X3 connector pins (1) and connector wiring (1) for evidence of overheating as
shown.
^ If evidence of overheating is observed, continue with this repair.
^ If evidence of overheating is not observed refer to the appropriate DTCs in Engine Cooling or
Symptoms - Engine Cooling in SI.
19. Position a ruler on the top of the upper radiator support (2) as shown. Align the ruler with the
arrows (1) and mark the 165 mm (6.5 in) area with a
paint stick or suitable marker.
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4541
1. Position the inboard edge of the cooling fan relay bracket (3) that was supplied with the revised
harness assembly, 22 mm (0.86 in) from the
outboard edge of the RH engine mount strut and tightly against the back edge of the radiator
support.
Note Align/adjust the ends of the bracket (3) over the radiator (2) slightly if necessary so that the
holes in the bracket DO NOT sit over any spot welds (1).
2. Mark the location of the holes in the bracket on the upper radiator support. Drill the holes using a
5 mm (3/16 in) drill bit.
20. Secure the bracket and relay assembly to the radiator core support using the rivets that were
supplied. 21. Remove the screw from the top of the windshield washer solvent container filler neck
at the RF fender flange in order to provide additional
clearance for routing the revised harness.
22. Route the revised harness (1) out from the engine compartment through the opening.
Note Route the maxi fuse leads one at a time through the fender flange opening.
Route the harness back into the engine compartment between the windshield washer solvent
container filler neck (2) and the RF fender flange.
23. Verify the proper routing of the harness as shown.
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4542
24. Using a suitable tool, open the engine harness conduit (3) for the X1 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- High Speed Cooling Fan Relay Control Circuit
- Low Speed Cooling Fan Relay Control Circuit
25. Using a suitable tool, open the engine harness conduit (4) for the X3 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Low Reference Circuit
- Cooling Fan - Left Supply Voltage Circuit
Important Examine the cooling fan supply voltage and low reference circuit wires for discoloration,
loss of insulation and brittleness in order to determine a good point to cut and splice.
26. When performing the following steps, adjust the location of the cuts at least 40 mm (1.5 in)
apart in order to allow the splices to lay end to end.
1. Cut both of the fan supply voltage circuits approximately 100 mm (4 in) from the entry point at
the fuse block or at a point where the
insulation and flexibility of the wire appear normal.
2. Cut the fan low reference circuit approximately 100 mm (4 in) from the entry point at the fuse
block or at a point where the insulation and
flexibility of the wire appear normal.
3. Cut both of the fan relay control circuits approximately 100 mm (4 in) from the entry point at the
fuse block.
27. Strip approximately 7.5 mm (0.313 in) of insulation from each of the five wires to be spliced.
1. Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. 2. If the
wire is damaged, repeat this procedure after removing the damaged section.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the DuraSeal splices.
28. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a green DuraSeal splice sleeve in nest
(1) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (1).
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4543
29. Insert the D-BU High Speed Cooling Fan Relay Control circuit wire (1) into the barrel (2) of the
splice sleeve until the wire hits the barrel stop (3).
30. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp. 31. Repeat steps 29 and 30 for the opposite end of the splice.
32. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
33. Repeat steps 28 through 32 for the D-GN Low Speed Cooling Fan Relay Control Circuit wire.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the Dura Seal splices.
Part # 2
34. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a yellow DuraSeal splice sleeve in nest
(3) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (3).
35. Insert the Cooling Fan - Left Low Reference circuit wire (1) into the barrel (2) of the splice
sleeve until the wire hits the barrel stop (3).
36. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp.
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
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Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4544
37. Repeat steps 35 and 36 for the opposite end of the splice.
38. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
39. Repeat steps 34 through 38 for the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan Relay Control Circuit wires coming from the
ECM back into the respective conduit for the harness
and tape as needed.
41. Route the new spliced High Speed and Low Speed Cooling Fan Relay Control Circuit wires
under the fuse block and toward the RH fender flange.
42. Insert any excess wire length for the Cooling Fan Low Reference Circuit, Right Supply Voltage
Circuit and Left Supply Voltage Circuit back into
the conduit (1) from which it was extracted in the area by the RH fender flange and tape as
needed.
43. Install the ground wire grommet from the revised harness assembly at the existing G 100
ground location (1) as shown.
Tighten Tighten the fastener to 7 Nm (62 lb in).
44. Install and seat the X1 and X3 electrical connectors into the fuse block. Verify the proper
positioning of all four connectors in the fuse block.
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Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4545
45. Install the electrical center board (2). Ensure that the tabs have locked in place.
Install the fasteners (1).
Tighten Tighten the fasteners to 7 Nm (62 lb in).
46. Install the forward lamp battery supply harness terminal and the fusible links (1) to the LH and
RH fuse block battery studs in their original
positions and orientations.
47. Route the shortest Maxi-Fuse ring terminal lead (2) to the RH fuse block stud (2). Maintain
sufficient clearance.
Route the longest Maxi-Fuse ring terminal lead (1) over the top of the fuse block to the LH fuse
block stud (1). Maintain sufficient clearance.
Tighten Tighten the fasteners to 7 Nm (62 lb in).
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Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4546
48. Install the fuse block underhood electrical center cover (1). 49. Enclose as much as possible of
the revised harness assembly in protective conduit and tape as needed.
Note Do not tip the battery more than 40 degrees during installation.
50. Install the battery. 51. Install the battery hold down and bolt.
Tighten Tighten the bolt to 18 Nm (13 lb ft).
52. Install the battery insulator.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
53. Install the positive battery cable terminal to the battery. 54. Tighten the positive battery cable
terminal nut.
Tighten Tighten the nut to 15 Nm (11 lb ft).
55. Snap closed the positive battery cable terminal cover.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
56. Install the negative battery cable terminal to the battery. Refer to Battery Negative Cable
Disconnection and Connection in SI. 57. Tighten the negative battery cable.
Tighten Tighten the nut to 15 Nm (11 lb ft).
58. Install the screw at the top of the windshield washer solvent container filler neck at the RF
fender flange.
Tighten Tighten the screw to 1Nm (9 lb in).
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Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan
Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4547
59. Install the retainer that secures the wiring harness to the bottom of the brace (2), then install the
upper diagonal brace.
Install the RH front fender upper diagonal brace bolts (1).
Tighten Tighten the bolts to 10 Nm (89 lb in).
60. Connect the electrical connector to the headlamp.
1. While installing the headlamp, guide the lock pin into the RH fender flange lock pin retainer. 2.
Install the headlamp bolt.
Tighten Tighten the bolt to 2Nm (18 lb in).
3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs. 62. Use the scan tool output controls to command
the Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1, 2 & 3 ON and OFF. Visually inspect both of
the cooling fans for the correct ON/OFF actions when activated. Refer to Engine Control Module
Scan Tool Output Controls in SI.
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Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set
Technical Service Bulletin # 09-06-03-007 Date: 090827
Cooling System - MIL ON DTC P0480/P0481 Set
TECHNICAL
Bulletin No.: 09-06-03-007
Date: August 27, 2009
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTC P0480 and/or P0481 Set Temperature Gage Indicates Hot - Cooling Fans Intermittent or Inoperative (Install Revised Cooling
Fan Relay and Harness Assembly)
Models:
2006-2009 Chevrolet Impala Police Sedan (RPO 9C1 Only) 2010 Chevrolet Impala Police Sedan
(with RPO 9C1 and without RPO WRH)
Condition
Some customers may comment that the instrument panel temperature gage indicates hot.
Some customers may also comment that the malfunction indicator lamp (MIL) is illuminated.
The technician may observe that DTC P0480 and/or P0481 are set as current or in history and/or
the engine cooling fans are intermittent or inoperative.
Cause
This condition may be caused by high underhood bussed electrical center (UBEC) temperatures
which may result in the cooling fans becoming intermittent or inoperative under certain operating
conditions.
Disclaimer
Part # 1
A revised engine cooling fan relay and harness assembly has been released, to reposition the
cooling fan relays for increased air circulation.
1. Turn OFF the ignition, all electrical components, lamps, accessories and the scan tool.
Open the hood.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4553
2. Remove the RH front fender upper diagonal brace bolts (1). Release the retainer that secures
the wiring harness from the bottom of the brace (2),
then remove the upper diagonal brace.
3. Loosen the negative battery cable terminal nut and remove the battery cable terminal from the
battery. Refer to Battery Negative Cable
Disconnection and Connection in SI.
4. Open the positive battery cable terminal cover, loosen the battery cable terminal nut and remove
the battery cable terminal from the battery.
5. Remove the battery insulator.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4554
6. Remove the battery hold down bolt and the hold down.
Note Do not tip the battery more than 40 degrees during removal.
7. Remove the battery. 8. Release the inner RH headlamp retainer by pulling the retainer upward.
9. Remove the RH headlamp assembly bolt.
10. Pull the headlamp from the outboard edge in order to release the lock pin from the fender
flange retainer. 11. Disconnect the electrical connector before removing the headlamp from the
vehicle.
12. Remove the fuse block underhood electrical center cover (1).
Note Observe the positions and orientations of the forward lamp battery supply harness terminal
and the fusible links on the studs before removing.
13. At the top of the fuse block disconnect the two fasteners on the fuse block battery studs and
remove the forward lamp battery supply harness
terminal and the fusible links. Remove the fasteners (1) securing the electrical center board (2).
14. Unlock the tabs on the electrical center board, then evenly lift up on the board in order to
remove it.
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Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4555
15. In the illustration above observe the orientation of the schematic for the fuse block. Identify the
location of connectors X1 and X3.
16. Locate and mark for reference, the following circuit terminals:
- Connector X1, Circuit 473, 0.35 D-BU, Pin C7, High Speed Cooling Fan Relay Control
- Connector X1, Circuit 335, 0.35 D-GN, Pin H7, Low Speed Cooling Fan Relay Control
17. Locate and mark for reference, the following circuit terminals:
- Connector X3, Circuit 409, 3 L-BU, Pin D1, Cooling Fan - Right Supply Voltage
- Connector X3, Circuit 532, 3 GY, Pin E1, Cooling Fan - Left Low Reference
- Connector X3, Circuit 504, 3 WH, Pin F2, Cooling Fan - Left Supply Voltage
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4556
18. Remove both fuse block engine harness connectors X1 (1) and X3 (2) from their respective
cavities.
1. Release and remove the bottom cover on both connectors.
2. Examine the X3 connector pins (1) and connector wiring (1) for evidence of overheating as
shown.
^ If evidence of overheating is observed, continue with this repair.
^ If evidence of overheating is not observed refer to the appropriate DTCs in Engine Cooling or
Symptoms - Engine Cooling in SI.
19. Position a ruler on the top of the upper radiator support (2) as shown. Align the ruler with the
arrows (1) and mark the 165 mm (6.5 in) area with a
paint stick or suitable marker.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4557
1. Position the inboard edge of the cooling fan relay bracket (3) that was supplied with the revised
harness assembly, 22 mm (0.86 in) from the
outboard edge of the RH engine mount strut and tightly against the back edge of the radiator
support.
Note Align/adjust the ends of the bracket (3) over the radiator (2) slightly if necessary so that the
holes in the bracket DO NOT sit over any spot welds (1).
2. Mark the location of the holes in the bracket on the upper radiator support. Drill the holes using a
5 mm (3/16 in) drill bit.
20. Secure the bracket and relay assembly to the radiator core support using the rivets that were
supplied. 21. Remove the screw from the top of the windshield washer solvent container filler neck
at the RF fender flange in order to provide additional
clearance for routing the revised harness.
22. Route the revised harness (1) out from the engine compartment through the opening.
Note Route the maxi fuse leads one at a time through the fender flange opening.
Route the harness back into the engine compartment between the windshield washer solvent
container filler neck (2) and the RF fender flange.
23. Verify the proper routing of the harness as shown.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4558
24. Using a suitable tool, open the engine harness conduit (3) for the X1 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- High Speed Cooling Fan Relay Control Circuit
- Low Speed Cooling Fan Relay Control Circuit
25. Using a suitable tool, open the engine harness conduit (4) for the X3 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Low Reference Circuit
- Cooling Fan - Left Supply Voltage Circuit
Important Examine the cooling fan supply voltage and low reference circuit wires for discoloration,
loss of insulation and brittleness in order to determine a good point to cut and splice.
26. When performing the following steps, adjust the location of the cuts at least 40 mm (1.5 in)
apart in order to allow the splices to lay end to end.
1. Cut both of the fan supply voltage circuits approximately 100 mm (4 in) from the entry point at
the fuse block or at a point where the
insulation and flexibility of the wire appear normal.
2. Cut the fan low reference circuit approximately 100 mm (4 in) from the entry point at the fuse
block or at a point where the insulation and
flexibility of the wire appear normal.
3. Cut both of the fan relay control circuits approximately 100 mm (4 in) from the entry point at the
fuse block.
27. Strip approximately 7.5 mm (0.313 in) of insulation from each of the five wires to be spliced.
1. Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. 2. If the
wire is damaged, repeat this procedure after removing the damaged section.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the DuraSeal splices.
28. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a green DuraSeal splice sleeve in nest
(1) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (1).
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4559
29. Insert the D-BU High Speed Cooling Fan Relay Control circuit wire (1) into the barrel (2) of the
splice sleeve until the wire hits the barrel stop (3).
30. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp. 31. Repeat steps 29 and 30 for the opposite end of the splice.
32. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
33. Repeat steps 28 through 32 for the D-GN Low Speed Cooling Fan Relay Control Circuit wire.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the Dura Seal splices.
Part # 2
34. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a yellow DuraSeal splice sleeve in nest
(3) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (3).
35. Insert the Cooling Fan - Left Low Reference circuit wire (1) into the barrel (2) of the splice
sleeve until the wire hits the barrel stop (3).
36. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4560
37. Repeat steps 35 and 36 for the opposite end of the splice.
38. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
39. Repeat steps 34 through 38 for the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan Relay Control Circuit wires coming from the
ECM back into the respective conduit for the harness
and tape as needed.
41. Route the new spliced High Speed and Low Speed Cooling Fan Relay Control Circuit wires
under the fuse block and toward the RH fender flange.
42. Insert any excess wire length for the Cooling Fan Low Reference Circuit, Right Supply Voltage
Circuit and Left Supply Voltage Circuit back into
the conduit (1) from which it was extracted in the area by the RH fender flange and tape as
needed.
43. Install the ground wire grommet from the revised harness assembly at the existing G 100
ground location (1) as shown.
Tighten Tighten the fastener to 7 Nm (62 lb in).
44. Install and seat the X1 and X3 electrical connectors into the fuse block. Verify the proper
positioning of all four connectors in the fuse block.
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4561
45. Install the electrical center board (2). Ensure that the tabs have locked in place.
Install the fasteners (1).
Tighten Tighten the fasteners to 7 Nm (62 lb in).
46. Install the forward lamp battery supply harness terminal and the fusible links (1) to the LH and
RH fuse block battery studs in their original
positions and orientations.
47. Route the shortest Maxi-Fuse ring terminal lead (2) to the RH fuse block stud (2). Maintain
sufficient clearance.
Route the longest Maxi-Fuse ring terminal lead (1) over the top of the fuse block to the LH fuse
block stud (1). Maintain sufficient clearance.
Tighten Tighten the fasteners to 7 Nm (62 lb in).
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4562
48. Install the fuse block underhood electrical center cover (1). 49. Enclose as much as possible of
the revised harness assembly in protective conduit and tape as needed.
Note Do not tip the battery more than 40 degrees during installation.
50. Install the battery. 51. Install the battery hold down and bolt.
Tighten Tighten the bolt to 18 Nm (13 lb ft).
52. Install the battery insulator.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
53. Install the positive battery cable terminal to the battery. 54. Tighten the positive battery cable
terminal nut.
Tighten Tighten the nut to 15 Nm (11 lb ft).
55. Snap closed the positive battery cable terminal cover.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
56. Install the negative battery cable terminal to the battery. Refer to Battery Negative Cable
Disconnection and Connection in SI. 57. Tighten the negative battery cable.
Tighten Tighten the nut to 15 Nm (11 lb ft).
58. Install the screw at the top of the windshield washer solvent container filler neck at the RF
fender flange.
Tighten Tighten the screw to 1Nm (9 lb in).
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Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 4563
59. Install the retainer that secures the wiring harness to the bottom of the brace (2), then install the
upper diagonal brace.
Install the RH front fender upper diagonal brace bolts (1).
Tighten Tighten the bolts to 10 Nm (89 lb in).
60. Connect the electrical connector to the headlamp.
1. While installing the headlamp, guide the lock pin into the RH fender flange lock pin retainer. 2.
Install the headlamp bolt.
Tighten Tighten the bolt to 2Nm (18 lb in).
3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs. 62. Use the scan tool output controls to command
the Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1, 2 & 3 ON and OFF. Visually inspect both of
the cooling fans for the correct ON/OFF actions when activated. Refer to Engine Control Module
Scan Tool Output Controls in SI.
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 4564
Radiator Cooling Fan Motor Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Radiator Cooling Fan Motor Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4597
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4608
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Radiator Cooling Fan Temperature Sensor / Switch: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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4809
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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4812
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
4820
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
4821
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
4822
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
4823
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
4824
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4834
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4835
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4836
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 >
Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4837
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan
> 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan
> 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4843
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan
> 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4844
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan
> 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4845
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan
> 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4846
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Page 4847
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
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Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Page 4849
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
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1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4856
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4857
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Information and Instructions > Page 4858
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Information and Instructions > Page 4859
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Information and Instructions > Page 4860
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4861
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Information and Instructions > Page 4862
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Information and Instructions > Page 4874
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4875
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Information and Instructions > Page 4877
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4878
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4879
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4880
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Information and Instructions > Page 4882
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Radiator Cooling Fan Temperature Sensor / Switch: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4885
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4887
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4888
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Information and Instructions > Page 4891
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Information and Instructions > Page 4958
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Information and Instructions > Page 4959
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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Information and Instructions > Page 4964
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Information and Instructions > Page 4967
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Information and Instructions > Page 4968
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4969
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4971
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 4972
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4974
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4975
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 4976
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 4978
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4980
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 4981
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Fan Shroud Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair > Page 4985
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators
Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators
INFORMATION
Bulletin No.: 05-06-02-001A
Date: July 16, 2008
Subject: Information On Aluminum Heater Core and/or Radiator Replacement
Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005
HUMMER H2
Supercede:
This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin
Number 05-06-02-001 (Section 06 - Engine/Propulsion System).
Important:
2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the
flushing procedure explained later in this bulletin.
The following information should be utilized when servicing aluminum heater core and/or radiators
on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient
inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check
should be performed whenever a heater core, radiator, or water pump is replaced. The following
procedures/ inspections should be done to verify proper coolant effectiveness.
Caution:
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge
tank cap is removed while the engine and radiator are still hot.
Important:
If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water
to the system, then the system should be completely flushed using the procedure explained later in
this bulletin.
Technician Diagnosis
^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion
protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the
measurement of coolant concentration. This must be done by using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer
uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or
the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the
coolant concentration fully and should not be used. The concentration levels should be between
50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees
Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be
flushed.
^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information
(SI) and/or the appropriate Service Manual for component location and condition for operation.
^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed
before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test
lead to the negative battery post and insert the other test lead into the radiator coolant, making sure
the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that
stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that
occurs when a device or accessory that is mounted to the radiator is energized. This type of current
could be caused from a poorly grounded cooling fan or some other accessory and can be verified
by watching the volt meter and turning on and off various accessories or engage the starter motor.
Before using one of the following flush procedures, the coolant recovery reservoir must be
removed, drained, cleaned and reinstalled before refilling the system.
Notice:
^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle.
^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The
repair cost would not be covered by your warranty. Too much water in the mixture can freeze and
crack the engine, radiator, heater core and other parts.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4990
Flushing Procedures using DEX-COOL(R)
Important:
The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in
Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a
service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior
to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the
Owner's Manual.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of
properly following the draining procedures in the appropriate Service Manual. Refill the system
using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the
vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear.
Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with
DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R),
P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear,
drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached
the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add
clean water to restore the coolant to the appropriate level.
Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration
levels should be between 50% and 65%.
Flushing Procedures using Conventional Silicated (Green Colored) Coolant
Important:
2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R).
The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color.
Silicated coolants are typically green in color and are required to be drained, flushed and refilled
every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated
coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's
Manual or Service Information (SI) for further information on OEM coolant.
Important:
Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when
adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and
green colored coolants will produce a brown coolant which may be a customer dissatisfier and will
not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by
GM Service and Parts Operations are green in color.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of
properly following the draining procedures in appropriate Service Manual. Refill the system using
clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3)
times to totally remove old coolant or until drained coolant is almost clear. Once the system is
completely flushed, refill the cooling system to a 50%-60% concentration with a good quality
ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L),
conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% good quality
ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N
88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water
(preferably distilled) to system until the level of the coolant mixture has reached the base of the
radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to
restore coolant to the appropriate level.
Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels
should be between 50% and 65%.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 4991
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core Cover Replacement
Heater Core: Service and Repair Heater Core Cover Replacement
Heater Core Cover Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core Cover Replacement > Page 4994
Heater Core: Service and Repair Heater Core Replacement
Heater Core Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4)
Heater Hose: Service and Repair Heater Inlet Hose Replacement (LS4)
Heater Inlet Hose Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Use J 38185 to reposition the heater inlet hose clamp at the heater pipe.
Important: Cap or plug the cooling components to prevent system contamination.
3. Remove the heater inlet hose (1) from the heater pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 4999
4. Use J 38185 to reposition the heater inlet hose clamp at the heater core. 5. Remove the heater
inlet hose (1) from the heater core.
Installation Procedure
1. Connect heater inlet hose (1) to the heater core. 2. Use J 38185 to reposition the heater inlet
hose to the heater core clamp.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5000
3. Install the heater inlet hose (1) to the heater pipe. 4. Use J 38185 to reposition the heater inlet
hose to the heater pipe clamp. 5. Fill the cooling system. Refer to Cooling System Draining and
Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5001
Heater Hose: Service and Repair Heater Outlet Hose Replacement (LS4)
Heater Outlet Hose Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Use J 38185 to reposition the heater outlet hose clamp to the heater pipe. 3. Remove the heater
outlet hose (2) from the heater pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5002
4. Use J 38185 to reposition the heater outlet hose to the heater core clamp. 5. Remove the heater
outlet hose (2) from the heater core.
Installation Procedure
1. Connect heater outlet hose (2) to the heater core. 2. Use J 38185 to reposition the heater outlet
hose to heater core clamp.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5003
3. Install the heater outlet hose (2) to the heater pipe. 4. Use J 38185 to reposition the heater outlet
hose to the heater pipe clamp. 5. Fill the cooling system. Refer to Cooling System Draining and
Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5004
Heater Hose: Service and Repair Heater Pipes Replacement (LS4)
Heater Pipes Replacement (LS4)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Remove the air cleaner assembly. 2. Drain the cooling system. Refer to Cooling System
Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
3. Release and reposition the heater inlet and outlet hose clamps using the J 38185.
Important: Cap or plug the cooling components to prevent system contamination.
4. Remove the heater hoses from heater pipes.
Notice: Do not apply excessive force on the heater core pipes during hose removal. Applying
excessive force on the heater core pipes may damage the heater core pipes.
5. Remove the heater pipe assembly retaining bolts from the rear the of engine.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5005
6. Remove the heater pipe assembly retaining bolt from the front of the engine. 7. Release and
reposition the heater pipe hose clamps at the engine using the J 38185. 8. Remove the heater pipe
hoses from the engine. 9. Remove the heater pipe assembly from the vehicle.
Installation Procedure
1. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the heater pipe assembly
at the engine and heater hoses. 2. Install the heater pipe assembly into position in the vehicle. 3.
Install the heater pipe hoses to the engine. 4. Reposition and release the heater pipe hose clamps
at the engine using the J 38185. 5. Loosely install the heater pipe assembly retaining bolt to the
front of the engine.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LS4) > Page 5006
Notice: Refer to Fastener Notice.
6. Install the heater pipe assembly retaining bolts to the rear of the engine.
Tighten all the heater pipe assembly bolts to 16 N.m (12 lb ft).
7. Connect heater hoses to the heater pipe assembly. 8. Install the heater hose clamps into
position using the J 38185. 9. Install the air cleaner assembly.
10. Fill the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Component Information > Service and Repair
Radiator Drain Plug: Service and Repair
Radiator Drain Cock Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Service Precautions
Radiator Cap: Service Precautions
Radiator Cap Removal Caution
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine
is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or
surge tank cap is removed while the engine and radiator are still hot.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Service Precautions > Page 5014
Radiator Cap: Testing and Inspection
Pressure Cap Testing
Tools Required
* J 24460-01 Cooling System Pressure Tester
* J 42401 Radiator Cap/Surge Tank Test Adapter
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine
is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or
surge tank cap is removed while the engine and radiator are still hot.
1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water.
Important: Lubricate J-42401 and pressure cap o-rings with coolant and press cap to seat o-ring on
J-42401 before turning to engage threads.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure
cap for the following conditions:
* Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap.
* Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions:
* The pressure cap does not release pressure which exceeds the rated pressure of the cap.
* The pressure cap does not hold the rated pressure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (RPO LS4) (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 5019
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (RPO LS4) (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set
Technical Service Bulletin # 09-06-03-007 Date: 090827
Cooling System - MIL ON DTC P0480/P0481 Set
TECHNICAL
Bulletin No.: 09-06-03-007
Date: August 27, 2009
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTC P0480 and/or P0481 Set Temperature Gage Indicates Hot - Cooling Fans Intermittent or Inoperative (Install Revised Cooling
Fan Relay and Harness Assembly)
Models:
2006-2009 Chevrolet Impala Police Sedan (RPO 9C1 Only) 2010 Chevrolet Impala Police Sedan
(with RPO 9C1 and without RPO WRH)
Condition
Some customers may comment that the instrument panel temperature gage indicates hot.
Some customers may also comment that the malfunction indicator lamp (MIL) is illuminated.
The technician may observe that DTC P0480 and/or P0481 are set as current or in history and/or
the engine cooling fans are intermittent or inoperative.
Cause
This condition may be caused by high underhood bussed electrical center (UBEC) temperatures
which may result in the cooling fans becoming intermittent or inoperative under certain operating
conditions.
Disclaimer
Part # 1
A revised engine cooling fan relay and harness assembly has been released, to reposition the
cooling fan relays for increased air circulation.
1. Turn OFF the ignition, all electrical components, lamps, accessories and the scan tool.
Open the hood.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 5029
2. Remove the RH front fender upper diagonal brace bolts (1). Release the retainer that secures
the wiring harness from the bottom of the brace (2),
then remove the upper diagonal brace.
3. Loosen the negative battery cable terminal nut and remove the battery cable terminal from the
battery. Refer to Battery Negative Cable
Disconnection and Connection in SI.
4. Open the positive battery cable terminal cover, loosen the battery cable terminal nut and remove
the battery cable terminal from the battery.
5. Remove the battery insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 5030
6. Remove the battery hold down bolt and the hold down.
Note Do not tip the battery more than 40 degrees during removal.
7. Remove the battery. 8. Release the inner RH headlamp retainer by pulling the retainer upward.
9. Remove the RH headlamp assembly bolt.
10. Pull the headlamp from the outboard edge in order to release the lock pin from the fender
flange retainer. 11. Disconnect the electrical connector before removing the headlamp from the
vehicle.
12. Remove the fuse block underhood electrical center cover (1).
Note Observe the positions and orientations of the forward lamp battery supply harness terminal
and the fusible links on the studs before removing.
13. At the top of the fuse block disconnect the two fasteners on the fuse block battery studs and
remove the forward lamp battery supply harness
terminal and the fusible links. Remove the fasteners (1) securing the electrical center board (2).
14. Unlock the tabs on the electrical center board, then evenly lift up on the board in order to
remove it.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 5031
15. In the illustration above observe the orientation of the schematic for the fuse block. Identify the
location of connectors X1 and X3.
16. Locate and mark for reference, the following circuit terminals:
- Connector X1, Circuit 473, 0.35 D-BU, Pin C7, High Speed Cooling Fan Relay Control
- Connector X1, Circuit 335, 0.35 D-GN, Pin H7, Low Speed Cooling Fan Relay Control
17. Locate and mark for reference, the following circuit terminals:
- Connector X3, Circuit 409, 3 L-BU, Pin D1, Cooling Fan - Right Supply Voltage
- Connector X3, Circuit 532, 3 GY, Pin E1, Cooling Fan - Left Low Reference
- Connector X3, Circuit 504, 3 WH, Pin F2, Cooling Fan - Left Supply Voltage
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 5032
18. Remove both fuse block engine harness connectors X1 (1) and X3 (2) from their respective
cavities.
1. Release and remove the bottom cover on both connectors.
2. Examine the X3 connector pins (1) and connector wiring (1) for evidence of overheating as
shown.
^ If evidence of overheating is observed, continue with this repair.
^ If evidence of overheating is not observed refer to the appropriate DTCs in Engine Cooling or
Symptoms - Engine Cooling in SI.
19. Position a ruler on the top of the upper radiator support (2) as shown. Align the ruler with the
arrows (1) and mark the 165 mm (6.5 in) area with a
paint stick or suitable marker.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Radiator
Cooling Fan Motor Relay: > 09-06-03-007 > Aug > 09 > Cooling System - MIL ON DTC P0480/P0481 Set > Page 5033
1. Position the inboard edge of the cooling fan relay bracket (3) that was supplied with the revised
harness assembly, 22 mm (0.86 in) from the
outboard edge of the RH engine mount strut and tightly against the back edge of the radiator
support.
Note Align/adjust the ends of the bracket (3) over the radiator (2) slightly if necessary so that the
holes in the bracket DO NOT sit over any spot welds (1).
2. Mark the location of the holes in the bracket on the upper radiator support. Drill the holes using a
5 mm (3/16 in) drill bit.
20. Secure the bracket and relay assembly to the radiator core support using the rivets that were
supplied. 21. Remove the screw from the top of the windshield washer solvent container filler neck
at the RF fender flange in order to provide additional
clearance for routing the revised harness.
22. Route the revised harness (1) out from the engine compartment through the opening.
Note Route the maxi fuse leads one at a time through the fender flange opening.
Route the harness back into the engine compartment between the windshield washer solvent
container filler neck (2) and the RF fender flange.
23. Verify the proper routing of the harness as shown.
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24. Using a suitable tool, open the engine harness conduit (3) for the X1 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- High Speed Cooling Fan Relay Control Circuit
- Low Speed Cooling Fan Relay Control Circuit
25. Using a suitable tool, open the engine harness conduit (4) for the X3 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Low Reference Circuit
- Cooling Fan - Left Supply Voltage Circuit
Important Examine the cooling fan supply voltage and low reference circuit wires for discoloration,
loss of insulation and brittleness in order to determine a good point to cut and splice.
26. When performing the following steps, adjust the location of the cuts at least 40 mm (1.5 in)
apart in order to allow the splices to lay end to end.
1. Cut both of the fan supply voltage circuits approximately 100 mm (4 in) from the entry point at
the fuse block or at a point where the
insulation and flexibility of the wire appear normal.
2. Cut the fan low reference circuit approximately 100 mm (4 in) from the entry point at the fuse
block or at a point where the insulation and
flexibility of the wire appear normal.
3. Cut both of the fan relay control circuits approximately 100 mm (4 in) from the entry point at the
fuse block.
27. Strip approximately 7.5 mm (0.313 in) of insulation from each of the five wires to be spliced.
1. Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. 2. If the
wire is damaged, repeat this procedure after removing the damaged section.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the DuraSeal splices.
28. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a green DuraSeal splice sleeve in nest
(1) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (1).
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29. Insert the D-BU High Speed Cooling Fan Relay Control circuit wire (1) into the barrel (2) of the
splice sleeve until the wire hits the barrel stop (3).
30. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp. 31. Repeat steps 29 and 30 for the opposite end of the splice.
32. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
33. Repeat steps 28 through 32 for the D-GN Low Speed Cooling Fan Relay Control Circuit wire.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the Dura Seal splices.
Part # 2
34. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a yellow DuraSeal splice sleeve in nest
(3) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (3).
35. Insert the Cooling Fan - Left Low Reference circuit wire (1) into the barrel (2) of the splice
sleeve until the wire hits the barrel stop (3).
36. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp.
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37. Repeat steps 35 and 36 for the opposite end of the splice.
38. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
39. Repeat steps 34 through 38 for the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan Relay Control Circuit wires coming from the
ECM back into the respective conduit for the harness
and tape as needed.
41. Route the new spliced High Speed and Low Speed Cooling Fan Relay Control Circuit wires
under the fuse block and toward the RH fender flange.
42. Insert any excess wire length for the Cooling Fan Low Reference Circuit, Right Supply Voltage
Circuit and Left Supply Voltage Circuit back into
the conduit (1) from which it was extracted in the area by the RH fender flange and tape as
needed.
43. Install the ground wire grommet from the revised harness assembly at the existing G 100
ground location (1) as shown.
Tighten Tighten the fastener to 7 Nm (62 lb in).
44. Install and seat the X1 and X3 electrical connectors into the fuse block. Verify the proper
positioning of all four connectors in the fuse block.
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45. Install the electrical center board (2). Ensure that the tabs have locked in place.
Install the fasteners (1).
Tighten Tighten the fasteners to 7 Nm (62 lb in).
46. Install the forward lamp battery supply harness terminal and the fusible links (1) to the LH and
RH fuse block battery studs in their original
positions and orientations.
47. Route the shortest Maxi-Fuse ring terminal lead (2) to the RH fuse block stud (2). Maintain
sufficient clearance.
Route the longest Maxi-Fuse ring terminal lead (1) over the top of the fuse block to the LH fuse
block stud (1). Maintain sufficient clearance.
Tighten Tighten the fasteners to 7 Nm (62 lb in).
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48. Install the fuse block underhood electrical center cover (1). 49. Enclose as much as possible of
the revised harness assembly in protective conduit and tape as needed.
Note Do not tip the battery more than 40 degrees during installation.
50. Install the battery. 51. Install the battery hold down and bolt.
Tighten Tighten the bolt to 18 Nm (13 lb ft).
52. Install the battery insulator.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
53. Install the positive battery cable terminal to the battery. 54. Tighten the positive battery cable
terminal nut.
Tighten Tighten the nut to 15 Nm (11 lb ft).
55. Snap closed the positive battery cable terminal cover.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
56. Install the negative battery cable terminal to the battery. Refer to Battery Negative Cable
Disconnection and Connection in SI. 57. Tighten the negative battery cable.
Tighten Tighten the nut to 15 Nm (11 lb ft).
58. Install the screw at the top of the windshield washer solvent container filler neck at the RF
fender flange.
Tighten Tighten the screw to 1Nm (9 lb in).
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59. Install the retainer that secures the wiring harness to the bottom of the brace (2), then install the
upper diagonal brace.
Install the RH front fender upper diagonal brace bolts (1).
Tighten Tighten the bolts to 10 Nm (89 lb in).
60. Connect the electrical connector to the headlamp.
1. While installing the headlamp, guide the lock pin into the RH fender flange lock pin retainer. 2.
Install the headlamp bolt.
Tighten Tighten the bolt to 2Nm (18 lb in).
3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs. 62. Use the scan tool output controls to command
the Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1, 2 & 3 ON and OFF. Visually inspect both of
the cooling fans for the correct ON/OFF actions when activated. Refer to Engine Control Module
Scan Tool Output Controls in SI.
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Technical Service Bulletin # 09-06-03-007 Date: 090827
Cooling System - MIL ON DTC P0480/P0481 Set
TECHNICAL
Bulletin No.: 09-06-03-007
Date: August 27, 2009
Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTC P0480 and/or P0481 Set Temperature Gage Indicates Hot - Cooling Fans Intermittent or Inoperative (Install Revised Cooling
Fan Relay and Harness Assembly)
Models:
2006-2009 Chevrolet Impala Police Sedan (RPO 9C1 Only) 2010 Chevrolet Impala Police Sedan
(with RPO 9C1 and without RPO WRH)
Condition
Some customers may comment that the instrument panel temperature gage indicates hot.
Some customers may also comment that the malfunction indicator lamp (MIL) is illuminated.
The technician may observe that DTC P0480 and/or P0481 are set as current or in history and/or
the engine cooling fans are intermittent or inoperative.
Cause
This condition may be caused by high underhood bussed electrical center (UBEC) temperatures
which may result in the cooling fans becoming intermittent or inoperative under certain operating
conditions.
Disclaimer
Part # 1
A revised engine cooling fan relay and harness assembly has been released, to reposition the
cooling fan relays for increased air circulation.
1. Turn OFF the ignition, all electrical components, lamps, accessories and the scan tool.
Open the hood.
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Page 5045
2. Remove the RH front fender upper diagonal brace bolts (1). Release the retainer that secures
the wiring harness from the bottom of the brace (2),
then remove the upper diagonal brace.
3. Loosen the negative battery cable terminal nut and remove the battery cable terminal from the
battery. Refer to Battery Negative Cable
Disconnection and Connection in SI.
4. Open the positive battery cable terminal cover, loosen the battery cable terminal nut and remove
the battery cable terminal from the battery.
5. Remove the battery insulator.
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Page 5046
6. Remove the battery hold down bolt and the hold down.
Note Do not tip the battery more than 40 degrees during removal.
7. Remove the battery. 8. Release the inner RH headlamp retainer by pulling the retainer upward.
9. Remove the RH headlamp assembly bolt.
10. Pull the headlamp from the outboard edge in order to release the lock pin from the fender
flange retainer. 11. Disconnect the electrical connector before removing the headlamp from the
vehicle.
12. Remove the fuse block underhood electrical center cover (1).
Note Observe the positions and orientations of the forward lamp battery supply harness terminal
and the fusible links on the studs before removing.
13. At the top of the fuse block disconnect the two fasteners on the fuse block battery studs and
remove the forward lamp battery supply harness
terminal and the fusible links. Remove the fasteners (1) securing the electrical center board (2).
14. Unlock the tabs on the electrical center board, then evenly lift up on the board in order to
remove it.
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Page 5047
15. In the illustration above observe the orientation of the schematic for the fuse block. Identify the
location of connectors X1 and X3.
16. Locate and mark for reference, the following circuit terminals:
- Connector X1, Circuit 473, 0.35 D-BU, Pin C7, High Speed Cooling Fan Relay Control
- Connector X1, Circuit 335, 0.35 D-GN, Pin H7, Low Speed Cooling Fan Relay Control
17. Locate and mark for reference, the following circuit terminals:
- Connector X3, Circuit 409, 3 L-BU, Pin D1, Cooling Fan - Right Supply Voltage
- Connector X3, Circuit 532, 3 GY, Pin E1, Cooling Fan - Left Low Reference
- Connector X3, Circuit 504, 3 WH, Pin F2, Cooling Fan - Left Supply Voltage
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Page 5048
18. Remove both fuse block engine harness connectors X1 (1) and X3 (2) from their respective
cavities.
1. Release and remove the bottom cover on both connectors.
2. Examine the X3 connector pins (1) and connector wiring (1) for evidence of overheating as
shown.
^ If evidence of overheating is observed, continue with this repair.
^ If evidence of overheating is not observed refer to the appropriate DTCs in Engine Cooling or
Symptoms - Engine Cooling in SI.
19. Position a ruler on the top of the upper radiator support (2) as shown. Align the ruler with the
arrows (1) and mark the 165 mm (6.5 in) area with a
paint stick or suitable marker.
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Page 5049
1. Position the inboard edge of the cooling fan relay bracket (3) that was supplied with the revised
harness assembly, 22 mm (0.86 in) from the
outboard edge of the RH engine mount strut and tightly against the back edge of the radiator
support.
Note Align/adjust the ends of the bracket (3) over the radiator (2) slightly if necessary so that the
holes in the bracket DO NOT sit over any spot welds (1).
2. Mark the location of the holes in the bracket on the upper radiator support. Drill the holes using a
5 mm (3/16 in) drill bit.
20. Secure the bracket and relay assembly to the radiator core support using the rivets that were
supplied. 21. Remove the screw from the top of the windshield washer solvent container filler neck
at the RF fender flange in order to provide additional
clearance for routing the revised harness.
22. Route the revised harness (1) out from the engine compartment through the opening.
Note Route the maxi fuse leads one at a time through the fender flange opening.
Route the harness back into the engine compartment between the windshield washer solvent
container filler neck (2) and the RF fender flange.
23. Verify the proper routing of the harness as shown.
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Page 5050
24. Using a suitable tool, open the engine harness conduit (3) for the X1 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- High Speed Cooling Fan Relay Control Circuit
- Low Speed Cooling Fan Relay Control Circuit
25. Using a suitable tool, open the engine harness conduit (4) for the X3 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Low Reference Circuit
- Cooling Fan - Left Supply Voltage Circuit
Important Examine the cooling fan supply voltage and low reference circuit wires for discoloration,
loss of insulation and brittleness in order to determine a good point to cut and splice.
26. When performing the following steps, adjust the location of the cuts at least 40 mm (1.5 in)
apart in order to allow the splices to lay end to end.
1. Cut both of the fan supply voltage circuits approximately 100 mm (4 in) from the entry point at
the fuse block or at a point where the
insulation and flexibility of the wire appear normal.
2. Cut the fan low reference circuit approximately 100 mm (4 in) from the entry point at the fuse
block or at a point where the insulation and
flexibility of the wire appear normal.
3. Cut both of the fan relay control circuits approximately 100 mm (4 in) from the entry point at the
fuse block.
27. Strip approximately 7.5 mm (0.313 in) of insulation from each of the five wires to be spliced.
1. Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. 2. If the
wire is damaged, repeat this procedure after removing the damaged section.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the DuraSeal splices.
28. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a green DuraSeal splice sleeve in nest
(1) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (1).
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Page 5051
29. Insert the D-BU High Speed Cooling Fan Relay Control circuit wire (1) into the barrel (2) of the
splice sleeve until the wire hits the barrel stop (3).
30. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp. 31. Repeat steps 29 and 30 for the opposite end of the splice.
32. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
33. Repeat steps 28 through 32 for the D-GN Low Speed Cooling Fan Relay Control Circuit wire.
Note Adding heat shrink tubing to the wire before splicing is advised in order to protect the integrity
of the Dura Seal splices.
Part # 2
34. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice
Crimp Tool. Place a yellow DuraSeal splice sleeve in nest
(3) as indicated above. Position the sleeve so that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the
proper nest (3).
35. Insert the Cooling Fan - Left Low Reference circuit wire (1) into the barrel (2) of the splice
sleeve until the wire hits the barrel stop (3).
36. Compress handles until the ratchet mechanism automatically releases in order to obtain a
secure crimp.
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Page 5052
37. Repeat steps 35 and 36 for the opposite end of the splice.
38. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually
moving to the open ends of the tubing. The tubing will
shrink completely as the heat is moved along the insulation. A small amount of sealant will come
out of the end of the tubing when sufficient shrinkage has occurred.
39. Repeat steps 34 through 38 for the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan Relay Control Circuit wires coming from the
ECM back into the respective conduit for the harness
and tape as needed.
41. Route the new spliced High Speed and Low Speed Cooling Fan Relay Control Circuit wires
under the fuse block and toward the RH fender flange.
42. Insert any excess wire length for the Cooling Fan Low Reference Circuit, Right Supply Voltage
Circuit and Left Supply Voltage Circuit back into
the conduit (1) from which it was extracted in the area by the RH fender flange and tape as
needed.
43. Install the ground wire grommet from the revised harness assembly at the existing G 100
ground location (1) as shown.
Tighten Tighten the fastener to 7 Nm (62 lb in).
44. Install and seat the X1 and X3 electrical connectors into the fuse block. Verify the proper
positioning of all four connectors in the fuse block.
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Page 5053
45. Install the electrical center board (2). Ensure that the tabs have locked in place.
Install the fasteners (1).
Tighten Tighten the fasteners to 7 Nm (62 lb in).
46. Install the forward lamp battery supply harness terminal and the fusible links (1) to the LH and
RH fuse block battery studs in their original
positions and orientations.
47. Route the shortest Maxi-Fuse ring terminal lead (2) to the RH fuse block stud (2). Maintain
sufficient clearance.
Route the longest Maxi-Fuse ring terminal lead (1) over the top of the fuse block to the LH fuse
block stud (1). Maintain sufficient clearance.
Tighten Tighten the fasteners to 7 Nm (62 lb in).
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Page 5054
48. Install the fuse block underhood electrical center cover (1). 49. Enclose as much as possible of
the revised harness assembly in protective conduit and tape as needed.
Note Do not tip the battery more than 40 degrees during installation.
50. Install the battery. 51. Install the battery hold down and bolt.
Tighten Tighten the bolt to 18 Nm (13 lb ft).
52. Install the battery insulator.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
53. Install the positive battery cable terminal to the battery. 54. Tighten the positive battery cable
terminal nut.
Tighten Tighten the nut to 15 Nm (11 lb ft).
55. Snap closed the positive battery cable terminal cover.
Note Clean any existing oxidation from the contact face of the battery terminal and battery cable
using a wire brush before installing the battery cable to the battery terminal.
56. Install the negative battery cable terminal to the battery. Refer to Battery Negative Cable
Disconnection and Connection in SI. 57. Tighten the negative battery cable.
Tighten Tighten the nut to 15 Nm (11 lb ft).
58. Install the screw at the top of the windshield washer solvent container filler neck at the RF
fender flange.
Tighten Tighten the screw to 1Nm (9 lb in).
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59. Install the retainer that secures the wiring harness to the bottom of the brace (2), then install the
upper diagonal brace.
Install the RH front fender upper diagonal brace bolts (1).
Tighten Tighten the bolts to 10 Nm (89 lb in).
60. Connect the electrical connector to the headlamp.
1. While installing the headlamp, guide the lock pin into the RH fender flange lock pin retainer. 2.
Install the headlamp bolt.
Tighten Tighten the bolt to 2Nm (18 lb in).
3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs. 62. Use the scan tool output controls to command
the Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1, 2 & 3 ON and OFF. Visually inspect both of
the cooling fans for the correct ON/OFF actions when activated. Refer to Engine Control Module
Scan Tool Output Controls in SI.
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Radiator Cooling Fan Motor Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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5059
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Radiator Cooling Fan Motor Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
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> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5196
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5197
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5198
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5199
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5205
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5206
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5207
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON
P0116/P1400 Set In Very Cold Temps > Page 5208
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated
Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Window
Noise When Operated
TECHNICAL
Bulletin No.: 06-08-64-033C
Date: April 29, 2008
Subject: Rubbing/Squealing/Grinding Noise When Door Glass Is Raised Or Lowered, Scratches in
Door Glass (Replace Door Glass Belt Sealing Strip)
Models: 2006-2008 Chevrolet Impala
Built Prior to November 2007
Supercede:
This bulletin is being revised to update the model years and add the build date. Please discard
Corporate Bulletin Number 06-08-64-033B (Section 08 - Body & Accessories).
Condition
Some customers may comment on a rubbing, squealing or grinding noise when opening or closing
the left or right front or rear door glass. They may also comment of scratches in the door glass.
Cause
This condition may be cause by dirt accumulating on the lip of the belt sealing strip.
Correction
Replace the door glass outer belt sealing strip with a newly designed outer belt sealing strip . Refer
to Front Side Door Window Belt Outer Sealing Strip Replacement or Rear Side Door Window Belt
Outer Sealing Strip Replacement in SI. Clean the glass with glass cleaner and if scuffs or scratches
are found it may be necessary to replace the glass as well.
Parts Information
Warranty Information
For vehicle repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 5214
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 5220
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 5221
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 5222
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 5223
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 5224
1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5229
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5230
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5231
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5232
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5233
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5234
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5235
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5236
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5237
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5238
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5239
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5240
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5241
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Radiator Cooling Fan Temperature Sensor / Switch: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information > Diagrams > Diagram Information and Instructions > Page 5343
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information > Diagrams > Diagram Information and Instructions > Page 5344
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5345
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Information > Diagrams > Diagram Information and Instructions > Page 5346
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5347
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5348
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5349
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information > Diagrams > Diagram Information and Instructions > Page 5350
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5351
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information > Diagrams > Diagram Information and Instructions > Page 5352
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5353
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information > Diagrams > Diagram Information and Instructions > Page 5354
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> Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5355
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications
Thermostat: Specifications
When the coolant temperature is below 91°C (195°F), the thermostat valve remains closed. This
prevents circulation of the coolant to the radiator and allows the engine to warm up quickly. After
the coolant temperature reaches 91°C (195°F), the thermostat valve will open.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications > Page 5359
Thermostat: Service and Repair
Engine Coolant Thermostat Replacement (LS4) (5.3L)
Special Tools
J 38185 Hose Clamp Pliers
Removal Procedure
1. Remove the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and
Deflector Replacement (See: Radiator/Service and
Repair) .
2. Reposition the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (RPO LS4) (See:
Radiator Hose/Service and Repair)Radiator Inlet
Hose Replacement (LZE, LZ4, LZG) (See: Radiator Hose/Service and Repair) .
3. Partially drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static
Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling
(LZE, LZ4, LZG, Static Fill).
4. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. 5. Remove
the radiator inlet hose from the water outlet housing.
6. Remove the water outlet housing bolts (302). 7. Remove the water outlet housing (303) and
O-ring seal (304). 8. Remove the thermostat (305). 9. Clean and inspect the water outlet housing
O-ring seal mating surfaces.
Installation Procedure
Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications > Page 5360
overheating and/or damage to the cooling system or the engine components/assembly.
1. Install the thermostat (305). 2. Install the O-ring seal (304) and water outlet housing (303).
Notice: Refer to Fastener Notice .
3. Install the water outlet housing bolts (302).
Tighten the bolts to 15 N.m (11 lb ft).
4. Install the radiator inlet hose to the water outlet housing. 5. Use the J 38185 in order to
reposition and install the hose clamp to the water outlet housing. 6. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Service and Repair)Cooling
System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE,
LZ4, LZG, Static Fill).
7. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (RPO LS4) (See:
Radiator Hose/Service and Repair)Radiator Inlet Hose
Replacement (LZE, LZ4, LZG) (See: Radiator Hose/Service and Repair) .
8. Install the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector
Replacement (See: Radiator/Service and
Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair
Thermostat Housing: Service and Repair
Engine Coolant Thermostat Housing Replacement (LS4) (5.3L)
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static
Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling
(LZE, LZ4, LZG, Static Fill).
2. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. 3. Remove
the radiator inlet hose from the water outlet housing.
4. Remove the water outlet housing bolts (302). 5. Remove the water outlet housing (303) and
O-ring seal (304). 6. Remove the thermostat (305). 7. Clean and inspect the water outlet housing
O-ring seal mating surfaces.
Installation Procedure
Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling system or the engine components/assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Page 5364
1. Install the thermostat (305). 2. Install the O-ring seal (304) and water outlet housing (303).
Notice: Refer to Fastener Notice .
3. Install the water outlet housing bolts (302).
Tighten the bolts to 15 N.m (11 lb ft).
4. Install the radiator inlet hose to the water outlet housing. 5. Use the J 38185 in order to
reposition and install the hose clamp to the water outlet housing. 6. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) (See: Service and Repair)Cooling
System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE,
LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Bolts ................................................................................................................................
...................................................... 10 N.m (89 lb in)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement
Water Pump: Service and Repair Coolant Pump Manifold Replacement
Coolant Pump Manifold Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Service and Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, Static Fill) (See: Service and Repair) .
2. Loosen the water pump bolts (318). 3. Remove the drive belt. Refer to Drive Belt Replacement Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair) .
4. Remove fluid from the power steering pump reservoir. 5. Remove the power steering pump
pulley. Refer to Power Steering Pump Pulley Replacement (LZ4/LZE/LZ9) Power Steering Pump
Pulley
Replacement (LS4) .
6. Disconnect the power steering hoses and pipes from the power steering pump and reservoir.
Refer to Power Steering Cooler Pipe/Hose
Replacement (3.5L and 3.9L) Power Steering Cooler Pipe/Hose Replacement (LS4) and Power
Steering Pressure Pipe/Hose Replacement (LZ4/LZE/LZ9) Power Steering Pressure Pipe/Hose
Replacement (LS4) .
7. Remove the bolt that retains a clip that retains the pressure pipe to the front of the engine. 8.
Remove the water pump bolts (318). 9. Remove the water pump (300) and gasket (314). Discard
the gasket.
10. Remove the camshaft position sensor. Refer to Camshaft Position Sensor Replacement . 11.
Unclip the wiring harness from the front of the engine.
12. Disconnect the engine coolant air bleed pipe hoses and clamps. Refer to Engine Coolant Air
Bleed Hose Replacement (LS4) (See: Coolant
Line/Hose/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement > Page 5370
13. Remove the three coolant pump manifold to cylinder head bolts. 14. Disconnect the heater
hoses at the coolant pump manifold. Refer to Heater Pipes Replacement (LS4) Heater Pipes
Replacement (LZE, LZ4, LZG)
.
15. Disconnect the radiator hoses from the coolant pump manifold. Refer to Radiator Inlet Hose
Replacement (RPO LS4) (See: Radiator Hose/Service
and Repair).
16. Remove the coolant pump manifold bolts (301). 17. Remove the coolant pump manifold (315)
and gaskets (306). Discard the gaskets. 18. Clean and inspect the water pump manifold mounting
surfaces.
19. Remove the thermostat housing bolts (302), if necessary. 20. Remove the thermostat housing
(303) and O-ring seal (304), if necessary. 21. Remove the thermostat (305), if necessary. 22.
Remove the power steering pump and reservoir from the coolant pump manifold. 23. Remove the
drive belt idler pulleys from the coolant pump manifold.
Installation Procedure
Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed.
The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the
passages of the cooling system or the engine components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling system or the engine components/assembly.
Important: All gasket surfaces are to be free of oil and other foreign material during assembly.
1. Install the drive belt idler pulleys to the coolant pump manifold. Refer to Drive Belt Idler Pulley
Replacement (See: Engine/Drive Belts, Mounts,
Brackets and Accessories/Idler Pulley/Service and Repair) .
2. Install the power steering pump and reservoir to the coolant pump manifold. Refer to Power
Steering Pump Replacement (LZ4/LZE/LZ9) Power
Steering Pump Replacement (LS4) and Remote Power Steering Fluid Reservoir Replacement .
3. Install the thermostat (305), if necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement > Page 5371
4. Install the thermostat housing (303) and O-ring seal (304), if necessary.
Notice: Refer to Fastener Notice .
5. Install the thermostat housing bolts (302), if necessary.
Tighten the bolts to 15 N.m (11 lb ft).
6. Install the water pump manifold (315) and NEW gaskets (306).
1. Tighten the M10 bolts to 60 N.m (44 lb ft). 2. Tighten the M8 bolts to 30 N.m (22 lb ft).
7. Install the water pump manifold bolts (301). 8. Install the camshaft position sensor. Refer to
Camshaft Position Sensor Replacement . 9. Install the cylinder head to coolant pump manifold
bolts.
10. Connect the engine coolant air bleed pipe hose and clamp.
11. Install the water pump (300) and a NEW gasket (314). 12. Install the water pump bolts (318)
until sung. 13. Connect the power steering pipes and hoses to the pump and reservoir. Refer to
Power Steering Cooler Pipe/Hose Replacement (3.5L and 3.9L)
Power Steering Cooler Pipe/Hose Replacement (LS4) and Power Steering Pressure Pipe/Hose
Replacement (LZ4/LZE/LZ9) Power Steering Pressure Pipe/Hose Replacement (LS4) .
14. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement
(LZ4/LZE/LZ9) Power Steering Pump Pulley
Replacement (LS4) .
15. Install the bolt that retains the power steering pipe to the front of the engine. 16. Install the
wiring harness to the clips on the front of the engine. 17. Install the drive belt. Refer to Drive Belt
Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement > Page 5372
Belt/Service and Repair) .
18. Tighten the water pump bolts (318).
Tighten the bolts to 10 N.m (89 lb in).
19. Connect the heater hoses to the coolant pump manifold. Refer to Heater Pipes Replacement
(LS4) Heater Pipes Replacement (LZE, LZ4, LZG) . 20. Connect the radiator hoses to the coolant
pump manifold. Refer to Radiator Inlet Hose Replacement. See: Radiator Hose/Service and Repair
21. Fill and bleed the power steering system. Refer to Checking and Adding Power Steering Fluid
and Power Steering System Bleeding . 22. Fill the cooling system. Refer to Cooling System
Draining and Filling (9C1, 9C3 Static Fill) (See: Service and Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) (See: Service and Repair)Cooling System
Draining and Filling (LZE, LZ4, LZG, Static Fill) (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement > Page 5373
Water Pump: Service and Repair Water Pump Replacement
Water Pump Replacement (LS4) (5.3L)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
(See: Service and Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE,
LZ4, LZG, Static Fill) .
2. Remove the battery and battery tray. Refer to Battery Tray Replacement (LS4) Battery Tray
Replacement (RPOs LZE/LZ4/LZ8) . 3. Remove the drive belt. Refer to Drive Belt Replacement Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair) .
4. Remove the water pump bolts (318). 5. Remove the water pump (300) and gasket (314). Discard
the gasket. 6. Clean and inspect the water pump gasket mating surfaces.
Installation Procedure
1. Install the water pump (300) and a NEW gasket (314).
Notice: Refer to Fastener Notice .
2. Tighten the water pump bolts (318).
Tighten the bolts to 10 N.m (89 lb in).
3. Install the drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair > Coolant Pump Manifold Replacement > Page 5374
Belt/Service and Repair) .
4. Install the battery tray and battery. Refer to Battery Tray Replacement (LS4) Battery Tray
Replacement (RPOs LZE/LZ4/LZ8) . 5. Fill the cooling system. Refer to Cooling System Draining
and Filling (9C1, 9C3 Static Fill) (See: Service and Repair)Cooling System Draining
and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE,
LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic Converter Replacement See: Service and
Repair 2. Remove the heated oxygen sensor (HO2S) wiring harness from the clips on the catalytic
converter heat shield.
3. Drill out the catalytic converter heat shield rivets. 4. Remove the catalytic converter heat shield.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair > Page 5380
1. Position the catalytic converter heat shield to the underbody. 2. Install NEW catalytic converter
heat shield rivets.
3. Install the HO2S wiring harness from the clips on the catalytic converter heat shield. 4. Install the
catalytic converter. Refer to Catalytic Converter Replacement See: Service and Repair
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Bolts - First Pass
............................................................................................................................................................
15 N.m (11 lb ft) Exhaust Manifold Bolts - Final Pass
...........................................................................................................................................................
20 N.m (15 lb ft)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side
Exhaust Manifold Replacement - Left Side (RPO LS4) (5.3L)
Removal Procedure
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine/Intake Manifold/Service and Repair) . 2. Remove the exhaust crossover pipe heat shield in
order to access the cross pipe to the exhaust manifold nuts. 3. Remove the exhaust crossover pipe
nuts from the left exhaust manifold. 4. Remove the left side spark plugs. Refer to Spark Plug
Replacement . 5. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube
Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick Dip Stick Tube/Service and Repair) .
6. Remove the exhaust manifold heat shield bolts (604). 7. Remove the exhaust manifold heat
shield (603). 8. Remove the heater hose retainer bolts in order to be able to remove the manifold.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 5386
9. Remove the exhaust manifold bolts.
10. Remove the exhaust manifold. 11. Remove and discard the exhaust manifold gasket.
Installation Procedure
Important:
* Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets my affect vehicle emissions and/or On Board Diagnostic
(OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
* DO NOT apply threadlock to the first three thread of the bolts.
1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or
equivalent to the threads of the exhaust manifold
bolts.
Notice: Refer to Fastener Notice .
2. Install a NEW exhaust manifold gasket, the exhaust manifold and bolts.
* Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side to side, and work toward the outside.
* Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side to side, and work toward the outside.
3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the
left cylinder head.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 5387
4. Install the exhaust manifold heat shield (603). 5. Install the exhaust manifold heat shield bolts
(604).
Tighten the bolts to 9 N.m (80 lb in).
6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement (See:
Engine/Engine Lubrication/Engine Oil Dip Stick Dip Stick Tube/Service and Repair) .
7. Install the left side spark plugs. Refer to Spark Plug Replacement .
8. Install the exhaust crossover pipe nuts from the left exhaust manifold.
Tighten the nuts to 25 N.m (18 lb ft).
9. Install the exhaust crossover pipe heat shield.
10. Install the heater pipe retainer bolts.
Tighten the bolts to 16 N.m (12 lb ft).
11. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 5388
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side
Exhaust Manifold Replacement - Right Side (RPO LS4) (5.3L)
Removal Procedure
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine/Intake Manifold/Service and Repair) . 2. Remove the spark plugs. Refer to Spark Plug
Replacement . 3. Remove the exhaust crossover pipe nuts from the right exhaust manifold. 4.
Disconnect the catalytic converter from the exhaust manifold. Refer to Catalytic Converter
Replacement (LS4) (See: Catalytic Converter/Service
and Repair)Catalytic Converter Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic
Converter/Service and Repair) .
5. Support the catalytic convertor and exhaust system with the mechanics wire. 6. Lower the
vehicle. 7. Remove the ignition coil. Refer to Ignition Coil Replacement . 8. Remove the heated
oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .
9. Remove the exhaust manifold heat shield bolts (604).
10. Remove the exhaust manifold heat shield (603).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 5389
11. Remove the exhaust manifold bolts. 12. Remove the exhaust manifold. 13. Remove and
discard the exhaust manifold gasket.
Installation Procedure
Important:
* Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets my affect vehicle emissions and/or On Board Diagnostic
(OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
* DO NOT apply threadlock to the first three thread of the bolts.
1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or
equivalent to the threads of the exhaust manifold
bolts.
Notice: Refer to Fastener Notice .
2. Install a NEW exhaust manifold gasket, the exhaust manifold and bolts.
* Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side to side, and work toward the outside.
* Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the bolts beginning with the center 2
bolts. Alternate from side to side, and work toward the outside.
3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the
right cylinder head.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 5390
4. Install the exhaust manifold heat shield (603). 5. Install the exhaust manifold heat shield bolts
(604).
Tighten the bolts to 9 N.m (80 lb in).
6. Install the O2 sensor. Refer to Spark Plug Replacement . 7. Raise the vehicle. 8. Remove the
mechanics wire from the exhaust system and connect the catalytic converter. Refer to Catalytic
Converter Replacement (LS4) (See:
Catalytic Converter/Service and Repair)Catalytic Converter Replacement (RPOs LZE/LZ4/LZ8)
(See: Catalytic Converter/Service and Repair) .
9. Install the exhaust crossover pipe nuts to the right exhaust manifold.
Tighten the nuts to 25 N.m (18 lb ft).
10. Install the ignition coil. Refer to Ignition Coil Replacement . 11. Install the spark plugs. Refer to
Spark Plug Replacement . 12. Install the fuel injector sight shield. Refer to Upper Intake Manifold
Sight Shield Replacement (See: Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information
> Service and Repair
Exhaust Pipe: Service and Repair
Exhaust Crossover Pipe Replacement (RPO LS4) (5.3L)
Removal Procedure
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine/Intake Manifold/Service and Repair) . 2. Remove the air cleaner outlet duct. Refer to Air
Cleaner Resonator Outlet Duct Replacement . 3. Remove the exhaust crossover pipe heat shield.
4. Remove the exhaust crossover pipe nuts. 5. Remove the exhaust crossover pipe. 6. Remove the
exhaust crossover pipe seal.
Installation Procedure
1. Install the exhaust crossover pipe seal to the exhaust crossover pipe at the right exhaust
manifold connection. 2. Install the exhaust crossover pipe.
Notice: Refer to Fastener Notice .
3. Install the exhaust crossover pipe nuts.
Tighten the nuts to 25 N.m (18 lb ft).
4. Install the exhaust crossover pipe heat shield. 5. Install the air cleaner outlet duct. Refer to Air
Cleaner Resonator Outlet Duct Replacement . 6. Install the engine sight shield. Refer to Upper
Intake Manifold Sight Shield Replacement (See: Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger >
Component Information > Service and Repair
Exhaust Pipe/Muffler Hanger: Service and Repair
Converter Hanger Assembly Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Using a suitable jack,
support the exhaust system, if necessary. 3. Remove and discard the catalytic converter pipe
hangers (1), if necessary.
Installation Procedure
1. Install the NEW catalytic converter pipe hangers (1), if necessary. 2. Remove the support from
the exhaust system, if necessary. 3. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Muffler Replacement (Dual Outlet)
Muffler: Service and Repair Muffler Replacement (Dual Outlet)
Muffler Replacement (Dual Outlet)
Removal Procedure
Important: The muffler is serviced as a complete assembly and cannot be serviced separately.
1. Remove the catalytic converter. Refer toCatalytic Converter Replacement (LS4) (See: Catalytic
Converter/Service and Repair)Catalytic Converter
Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
2. Support the exhaust system. 3. With the aid of an assistant, remove the exhaust system from the
exhaust hangers. 4. Clean the catalytic converter and the muffler mating surfaces.
Installation Procedure
1. With the aid of an assistant, install the muffler to the exhaust hangers. 2. Remove the support
from the exhaust system. 3. Install the catalytic converter. Refer to Catalytic Converter
Replacement (LS4) (See: Catalytic Converter/Service and Repair)Catalytic Converter
Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Muffler Replacement (Dual Outlet) > Page 5401
Muffler: Service and Repair Muffler Replacement (Single Outlet)
Muffler Replacement (Single Outlet)
Removal Procedure
Important: The muffler is serviced as a complete assembly and cannot be serviced separately.
1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LS4) (See: Catalytic
Converter/Service and Repair)Catalytic
Converter Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
2. Have an assistant support the muffler assembly. 3. Remove the muffler assembly from the
exhaust insulators. 4. Clean the catalytic converter to muffler mating surfaces.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Muffler Replacement (Dual Outlet) > Page 5402
1. Lubricate the insulators with spray lubricant. 2. With the aid of an assistant, install the muffler
assembly to the exhaust insulators. 3. Install the catalytic converter. Refer to Catalytic Converter
Replacement (LS4) (See: Catalytic Converter/Service and Repair)Catalytic Converter
Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair
Exhaust Pipe Gasket: Service and Repair
Exhaust Seal Replacement
Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LS4) (See: Catalytic
Converter/Service and Repair)Catalytic
Converter Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
2. Remove and discard the exhaust manifold pipe gasket (2), if equipped with regular production
options (RPOs) LZE/LZ9.
3. Remove and discard the exhaust manifold pipe gasket (1), if equipped with RPO LS4.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair > Page 5407
4. Remove and discard the catalytic converter to muffler gasket (2), if equipped with RPO LZE.
5. Remove and discard the catalytic converter to muffler seal, if equipped with RPOs LS4/LZ9.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair > Page 5408
1. Install a NEW catalytic converter to muffler seal, if equipped with RPOs LS4/LZ9.
2. Install a NEW catalytic converter to muffler gasket (2), if equipped with RPO LZE.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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3. Install a NEW exhaust manifold pipe gasket (1), if equipped with RPO LS4.
4. Install a NEW exhaust manifold pipe gasket (2), if equipped with RPOs LZE/LZ9. 5. Install the
catalytic converter. Refer to Catalytic Converter Replacement (LS4) (See: Catalytic
Converter/Service and Repair)Catalytic Converter
Replacement (RPOs LZE/LZ4/LZ8) (See: Catalytic Converter/Service and Repair) .
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Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
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During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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Disclaimer
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> Page 5420
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Near the Steering Column
1 - Instrument Panel Carrier 2 - Inflatable Restraint Steering Wheel Module 3 - Steering Column 4 Body Control Module (BCM)
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> Page 5421
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Body Control Module (BCM) X2
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Body Control Module (BCM) X3
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> Page 5424
Body Control Module (BCM) X4
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> Page 5425
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> Page 5426
Body Control Module (BCM) X5
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> Page 5427
Body Control Module (BCM) X6
Body Control Module (BCM) X7
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> Page 5428
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> Page 5429
Body Control Module: Service and Repair
Body Control Module Replacement
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5435
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5438
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5439
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
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3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
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Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
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Vehicle/Engine Compartment Component Views
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Engine Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Engine Control Module: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 5575
Engine Control Module: Connector Views
Component Connector End Views
Engine Control Module (ECM) X1 (LS4)
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Engine Control Module (ECM) X2 (LS4)
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Information and Instructions > Page 5577
Engine Control Module (ECM) X2 (LS4) (Pin 1 To 33)
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Engine Control Module (ECM) X2 (LS4) (Pin 34 To 73)
Engine Control Module (ECM) X3 (LS4)
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Engine Control Module: Electrical Diagrams
For information regarding diagrams for this component, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams/Engine Controls Diagram Index
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for ECM replacement, inspect the ECM first to see if the replacement is
the correct part. If the ECM is faulty, remove the ECM and install the new service ECM.
The new service ECM will not be programmed. You must program the new ECM. DTC P0602
indicates the EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch
the connector pins or the soldered components on the circuit board.
Notice: Always turn the ignition off when installing or removing the ECM connectors in order to
prevent damage to the components.
Removal Procedure
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life, if required. 2. Disconnect the negative battery cable. 3. Remove the left front inner fender
brace. 4. Remove the air cleaner assembly. 5. Disconnect the ECM electrical connectors (2).
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6. Remove the ECM from the air cleaner lower housing.
Installation Procedure
1. Install the ECM to the air cleaner lower housing.
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2. Connect the ECM electrical connectors (2). 3. Install the air cleaner assembly. 4. Install the left
front inner fender brace. 5. Connect the negative battery cable. 6. Program the new ECM. See:
Testing and Inspection/Programming and Relearning
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Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
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^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
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Air Injection Pump Relay: Diagrams
Component Connector End Views - Continued
Secondary Air Injection (AIR) Pump Relay (NU3)
Secondary Air Injection (AIR) Solenoid Relay (NU3)
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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and Instructions
Fuel Pump Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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and Instructions > Page 5604
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and Instructions > Page 5607
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and Instructions > Page 5609
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5613
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and Instructions > Page 5624
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and Instructions > Page 5625
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and Instructions > Page 5626
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and Instructions > Page 5627
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and Instructions > Page 5628
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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and Instructions > Page 5691
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5718
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 5719
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5720
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 5721
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5722
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5723
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5724
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 5725
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5726
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5727
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 5728
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 5732
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
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Page 5733
^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 5739
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 5740
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
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Page 5741
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Powertrain
Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Powertrain
Component Views > Page 5746
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Component Views > Page 5747
Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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Information and Instructions > Page 5836
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Information and Instructions > Page 5838
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Information and Instructions > Page 5839
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
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Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
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Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Information and Instructions > Page 6005
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 6012
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6017
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6018
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6019
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6020
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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6021
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
6022
1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6031
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6032
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6033
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6034
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6040
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6041
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6042
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For
Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 6043
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 6044
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 6045
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Page 6046
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
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1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6178
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Information and Instructions > Page 6179
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6180
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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Crankshaft Position Sensor Replacement > Page 6183
1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
Powertrain Component Views
Fuel Pump and Sender Assembly
1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
1. Remove the fuel sender assembly. 2. Using two flat-bladed tools, carefully pull both locking tabs
(1) outward while simultaneously lifting the level sensor.
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3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
Installation Procedure
1. Push in the electrical terminals (1) and ensure the terminals are secure.
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2. Carefully insert the level sensor until the locking tabs (1) snap into the locking position. 3. Install
the fuel sender assembly.
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Fuel Tank Pressure Sensor: Locations
Powertrain Component Views
Fuel Tank Components
1 - Fuel Tank 2 - Fuel Pump and Sender Assembly 3 - Fuel Tank Pressure (FTP) Sensor 4 Evaporative Emission (EVAP) Canister Vent Solenoid Valve
Fuel Pump and Sender Assembly
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1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations >
Powertrain Component Views
Intake Air Temperature Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Powertrain Component Views > Page 6202
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions
Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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and Instructions > Page 6213
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 6231
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 6232
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6237
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6241
Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 6335
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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and Instructions > Page 6337
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 6339
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6340
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
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5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
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2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Top of Engine (LS4)
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Page 6350
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1 15 - Fuel Injector 2 16 - Ignition
Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6
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Page 6351
20 - Ignition Coil 6
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Page 6352
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LS4)
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Page 6353
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor
electrical connector (2).
3. Remove the MAP sensor (714) from the intake manifold. 4. Remove the MAP sensor grommet
(715), if required.
Installation Procedure
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Page 6354
1. Lubricate the MAP sensor grommet with clean engine oil, if required. 2. Install the MAP sensor
grommet (715), if required. 3. Install the MAP sensor (714).
4. Connect the MAP sensor electrical connector (2). 5. Install the engine sight shield.
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Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
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15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
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Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
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Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
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1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: Recalls Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
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Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 6370
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 6371
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: All Technical Service Bulletins Campaign - Inspect/Replace Post-Catalyst O2
Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
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1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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Disclaimer
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Other Service Bulletins for Oxygen Sensor: > 09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Stabiltrak
Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Oxygen Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Underbody
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1 - Heated Oxygen Sensor (HO2S) 2
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Oxygen Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6505
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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and Instructions > Page 6506
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6507
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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and Instructions > Page 6508
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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and Instructions > Page 6509
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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and Instructions > Page 6511
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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and Instructions > Page 6512
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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and Instructions > Page 6513
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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and Instructions > Page 6514
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 6515
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 6517
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 6518
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6519
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 6520
Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LS4)
Heated Oxygen Sensor (HO2S) 2
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and Instructions > Page 6521
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Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated
Oxygen and Oxygen Sensor Notice > Page 6524
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen and Oxygen Sensor Notice > Page 6525
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen and Oxygen Sensor Notice > Page 6526
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen and Oxygen Sensor Notice > Page 6527
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
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Oxygen and Oxygen Sensor Notice > Page 6528
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
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Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Remove the intake manifold sight shield. 2. Remove the connector position assurance (CPA)
retainer (1). 3. Disconnect the bank 1 sensor 1 electrical connector (2).
4. Remove the bank 1 sensor 1 from the exhaust manifold.
Installation Procedure
Important: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before reinstallation.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 6531
1. If re-installing the old sensor, coat the threads with anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 1 sensor 1 to the exhaust manifold.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 1 sensor 1 electrical connector (2). 4. Install the CPA retainer (1). 5. Install the
intake manifold sight shield.
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 6532
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position
assurance (CPA) retainer. 3. Disconnect the bank 2 sensor 2 electrical connector.
4. Remove the bank 2 sensor 2 from the catalytic converter.
Installation Procedure
Important: A special anti-seize compound is use on the heated oxygen sensor (HO2S) threads.
The compound consists of liquid graphite and glass beads. The graphite tends to burns away, but
the glass beads remain, making the sensor easier to remove. New or service replacement sensors
already have the compound applied to the threads. If the sensor is removed from an exhaust
component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize
compound applied before reinstallation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 6533
1. If re-installing the old sensor, coat the threads with the anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 2 sensor 2 to the catalytic converter.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 2 sensor 2 electrical connector. 4. Install the CPA retainer. 5. Lower the
vehicle.
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information and Instructions > Page 6538
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6539
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6540
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6541
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6542
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6543
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6544
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6545
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6546
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6547
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6548
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6549
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6550
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6551
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6552
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6553
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6554
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6555
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6556
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6557
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6558
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6559
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6560
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6561
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6562
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Information and Instructions > Page 6563
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6564
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 6565
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Information and Instructions > Page 6566
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 6567
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 6568
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 6656
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 6657
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 6658
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 6659
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 6660
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 6661
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 6662
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6663
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 6664
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > 4T65-E Automatic Transaxle
Vehicle Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Vehicle Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
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Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
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Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair
).
3. Disconnect the vehicle speed sensor (VSS) electrical connector.
4. Remove the VSS bolt (9). 5. Remove the VSS (10) from the extension case.
6. Remove the O-ring (11) from the VSS (10).
Installation Procedure
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1. Install the O-ring (11) to the VSS (10).
2. Install the VSS (10).
Notice: Refer to Fastener Notice .
3. Install the VSS bolt (9).
Tighten the bolt (9) to 12 N.m (106 lb in).
4. Connect the VSS electrical connector. 5. Install the right front tire and wheel. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6.
Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
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Page 6677
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Page 6678
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
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Page 6679
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
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Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Views > Page 6684
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Component Views > Page 6685
Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information and Instructions > Page 6688
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Information and Instructions > Page 6689
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6690
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Information and Instructions > Page 6691
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 6692
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Information and Instructions > Page 6693
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Information and Instructions > Page 6694
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Information and Instructions > Page 6695
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Information and Instructions > Page 6696
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Information and Instructions > Page 6697
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Information and Instructions > Page 6698
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Information and Instructions > Page 6699
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Information and Instructions > Page 6700
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Information and Instructions > Page 6701
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information and Instructions > Page 6842
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 6937
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Instructions > Page 6962
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Instructions > Page 6966
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Instructions > Page 7099
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 7206
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Instructions > Page 7207
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 7208
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 7209
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 7210
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 7211
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 7212
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 7216
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Instructions > Page 7217
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
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Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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Position Sensor Replacement > Page 7220
1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
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7226
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
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> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
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> Procedures > Page 7229
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
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are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
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Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
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cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
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22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
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Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
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7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
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3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
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7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
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Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Page 7363
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Page 7364
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Page 7365
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7366
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Page 7367
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7368
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7369
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7370
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7371
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 7372
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7373
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7374
Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7375
5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7376
2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 7377
6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)..................................................................................................
..............................................345-414 kPa (50-60 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information > Page 7384
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7387
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7388
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the fuel pump relay when the ignition switch is turned ON. The control
module will disable the fuel pump relay within 2 seconds unless the control module detects ignition
reference pulses. The control module continues to enable the fuel pump relay as long as ignition
reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if
ignition reference pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
*
Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa
(50-60 psi).
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Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7389
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel
rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF
with a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the fuel pump module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Assembly Replacement
* Fuel Injector Replacement
* Fuel Tank Fuel Pump Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed >
System Information > Specifications
Idle Speed: Specifications
Not supplied by manufacturer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Disconnect the positive crankcase ventilation (PCV) tube from the air inlet duct.
2. Loosen the air inlet duct clamp at the throttle body. 3. Remove the air inlet duct from the throttle
body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 7397
4. Loosen the air inlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5.
Remove the air inlet duct from the MAF/IAT sensor.
Installation Procedure
1. Install the air inlet duct from the MAF/IAT sensor.
Notice: Refer to Fastener Notice.
2. Tighten the air inlet duct clamp at the MAF/IAT sensor.
Tighten the clamp to 3 N.m (27 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 7398
3. Install the air inlet duct to the throttle body. 4. Tighten the air inlet duct clamp at the throttle body.
Tighten the clamp to 3 N.m (27 lb in).
5. Connect the PCV tube to the air inlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. 2. Release the spring clamps on top of the air cleaner
housing. 3. Remove the air cleaner housing cover. 4. Remove the air filter element.
Installation Procedure
1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Engage the spring
clamps on top of the air cleaner housing. 4. Install the air cleaner outlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 7407
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 7408
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 7409
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
...........................................................1-8-7-2-6-5-4-3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
...........................................................397-1,337 ohms
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 7416
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
following conditions:
1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 7417
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the spark plug.
2. Remove the spark plug wire from the ignition coil (724).
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil (724). 2. Install the spark plug wire to the spark plug.
3. Inspect the spark plug wire for proper installation:
1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.......................................................1.02 mm - 0.040 in Spark Plug Torque..........................................
................................................................................................................................................15 N.m 11 lb ft
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 7421
Spark Plug: Application and ID
Spark Plug
Type..........................................................................................................................................GM
P/N 12571164 (AC Spark Plug P/N 41-985)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 7422
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - colder plug
- Pre-ignition causing spark plug and/or engine damage - hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 7423
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively-wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over-torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes reduce or eliminates the gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 7424
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot
engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug
thread damage or cylinder head damage.
1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using
compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 7425
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed.
Spark plug gap: 1.016 mm (0.040 in).
3. Hand start the spark plug in the corresponding cylinder.
Notice: Refer to Fastener Notice.
4. Tighten the spark plug.
Tighten the plug to 15 N.m (11 lb ft).
5. Install the spark plug wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications
Compression Check: Specifications
The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa (100 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications > Page 7429
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 7434
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 7435
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 7436
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Powertrain Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Powertrain Component Views > Page 7441
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Powertrain Component Views > Page 7442
Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7445
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7446
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7447
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7448
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7449
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7450
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7451
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7452
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7453
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7454
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7455
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7456
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7457
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7458
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7459
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7460
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7461
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7462
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7463
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7464
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7465
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7466
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7467
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7468
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7469
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7470
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7471
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7472
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7473
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7474
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7496
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7518
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Component Information > Diagrams > Diagram Information and Instructions > Page 7521
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7525
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7532
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7537
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7538
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7553
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7554
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7556
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7558
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7559
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7561
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7563
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7564
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7565
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7566
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7567
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7568
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7569
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7570
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7571
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7572
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 7573
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 7574
1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Powertrain Component Views
Intake Air Temperature Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Powertrain Component Views > Page 7579
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Powertrain Component Views > Page 7580
Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Page 7581
Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Page 7582
Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Locations > Page 7583
1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Powertrain Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Powertrain Component Views > Page 7588
Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 7589
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 7590
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 7591
Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page
7596
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page
7597
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page
7598
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7599
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Near the Steering Column
1 - Instrument Panel Carrier 2 - Inflatable Restraint Steering Wheel Module 3 - Steering Column 4 Body Control Module (BCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7600
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7601
Body Control Module (BCM) X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7602
Body Control Module (BCM) X3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7603
Body Control Module (BCM) X4
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7604
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7605
Body Control Module (BCM) X5
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7606
Body Control Module (BCM) X6
Body Control Module (BCM) X7
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7607
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Page 7608
Body Control Module: Service and Repair
Body Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7732
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7736
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7738
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7740
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7741
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant
Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very
Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant
Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very
Cold Temps > Page 7752
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant
Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very
Cold Temps > Page 7753
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant
Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very
Cold Temps > Page 7754
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant
Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very
Cold Temps > Page 7755
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In
Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In
Very Cold Temps > Page 7761
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In
Very Cold Temps > Page 7762
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In
Very Cold Temps > Page 7763
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In
Very Cold Temps > Page 7764
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7765
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7766
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7767
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 7768
1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
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Component Information > Diagrams > Diagram Information and Instructions > Page 7776
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7802
Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 7804
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7805
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7847
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7848
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7849
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7850
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7851
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7852
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7854
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7855
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7856
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7857
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7858
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7859
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7861
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7862
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7863
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7865
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7866
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7867
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7869
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7872
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7876
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7878
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7879
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7880
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7881
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7883
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7884
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7885
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7886
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7887
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7888
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7889
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7890
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7892
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7893
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7894
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7895
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7896
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7897
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7898
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 7899
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7900
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7901
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 7904
1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 7905
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic
Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/P Code Charts/P0315 See: Testing and Inspection/Diagnostic Trouble
Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams
Data Link Connector: Diagrams
Data Link Connector (DLC)
Connector Part Information
- OEM: 15488184
- Service: 19115029
- Description: 16-Way F Metri-Pack 150 Series (BK)
Terminal Part Information
- Terminal/Tray: 12129484/19
- Core/Insulation Crimp: E/C
- Release Tool/Test Probe: 12094429/J-35616-2A (GY)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Page 7909
Data Link Connector: Service and Repair
Data Link Connector Replacement
Removal Procedure
1. Disengage the data link connector (DLC) tab (1). 2. Remove the DLC from the instrument panel
(I/P) trim pad.
Installation Procedure
1. Align the DLC to the I/P trim pad. 2. Slide the DLC upward in order to engage the tab (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation
Electronic Throttle Actuator: Description and Operation
Throttle Actuator Control (TAC) System Description
Purpose
The throttle actuator control (TAC) system delivers improved throttle response and greater
reliability and eliminates the need for mechanical cable. The TAC system performs the following
functions:
* Accelerator pedal position sensing
* Throttle positioning to meet driver and engine demands
* Throttle position sensing
* Internal diagnostics
* Cruise control functions
* Manage TAC electrical power consumption
The TAC system includes the following components:
* The accelerator pedal position (APP) sensors
* The throttle body assembly
* The engine control module (ECM)
Accelerator Pedal Position (APP) Sensor
The accelerator pedal contains 2 individual APP sensors within the assembly. The Accelerator
Pedal Position (APP) sensors 1 and 2 are potentiometer type sensors each with 3 circuits:
* A 5-volt reference circuit
* A low reference circuit
* A signal circuit
The APP sensors are used to determine the pedal angle. The engine control module (ECM)
provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors
provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal
voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated.
The APP sensor 2 signal voltage at rest position is near 0.5 volt and increases to more than 2 volts
as the pedal is actuated.
Throttle Body Assembly
The throttle assembly contains the following components:
* The throttle blade
* The throttle actuator motor
* The throttle position (TP) sensor 1 and 2
The throttle body functions similar to a conventional throttle body with the following exceptions:
* An electric motor opens and closes the throttle valve.
* The throttle blade is spring loaded in both directions and the default position is slightly open.
* There are 2 individual TP sensors within the throttle body assembly.
The TP sensors are used to determine the throttle plate angle. The TP sensors provide the engine
control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor
1 signal voltage at closed throttle is above 4 volts and decreases as the throttle plate is opened.
The TP sensor 2 signal voltage at closed throttle is below 1 volt and increases as the throttle plate
is opened.
Engine Control Module
The engine control module (ECM) is the control center for the throttle actuator control (TAC)
system. The ECM determines the drivers intent and then calculates the appropriate throttle
response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to
the TAC motor.
Modes of Operation
Normal Mode
During the operation of the throttle actuator control (TAC) system, several modes or functions are
considered normal. The following modes may be entered during normal operation:
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* Minimum pedal value-At key-up the engine control module (ECM) updates the learned minimum
pedal value.
* Minimum throttle position (TP) values-At key-up the ECM updates the learned minimum TP value.
In order to learn the minimum TP value, the throttle blade is moved to the closed position.
* Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the
ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse
width several times to the throttle actuator motor in the closing direction.
* Battery saver mode-After a predetermined time without engine RPM, the ECM commands the
battery saver mode. During the battery saver mode, the TAC module removes the voltage from the
motor control circuits, which removes the current draw used to maintain the idle position and allows
the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine
power mode. Reduced engine power may cause one or more of the following conditions:
* Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control;
however, the vehicle acceleration is limited.
* Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control;
however, the maximum throttle opening is limited.
* Throttle default mode-The ECM will turn off the throttle actuator motor and the throttle will return
to the spring loaded default position.
* Forced idle mode-The ECM will perform the following actions:
- Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if
the throttle is turned off.
- Ignore the accelerator pedal input.
* Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 7918
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 7919
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 7920
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 7921
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
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3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
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Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Front of Vehicle/Engine Compartment Component Views
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Engine Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Component Information > Diagrams > Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Component Information > Diagrams > Diagram Information and Instructions > Page 8043
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Engine Control Module: Connector Views
Component Connector End Views
Engine Control Module (ECM) X1 (LS4)
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Engine Control Module (ECM) X2 (LS4)
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Engine Control Module (ECM) X2 (LS4) (Pin 1 To 33)
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Engine Control Module (ECM) X2 (LS4) (Pin 34 To 73)
Engine Control Module (ECM) X3 (LS4)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for ECM replacement, inspect the ECM first to see if the replacement is
the correct part. If the ECM is faulty, remove the ECM and install the new service ECM.
The new service ECM will not be programmed. You must program the new ECM. DTC P0602
indicates the EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch
the connector pins or the soldered components on the circuit board.
Notice: Always turn the ignition off when installing or removing the ECM connectors in order to
prevent damage to the components.
Removal Procedure
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life, if required. 2. Disconnect the negative battery cable. 3. Remove the left front inner fender
brace. 4. Remove the air cleaner assembly. 5. Disconnect the ECM electrical connectors (2).
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6. Remove the ECM from the air cleaner lower housing.
Installation Procedure
1. Install the ECM to the air cleaner lower housing.
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2. Connect the ECM electrical connectors (2). 3. Install the air cleaner assembly. 4. Install the left
front inner fender brace. 5. Connect the negative battery cable. 6. Program the new ECM. See:
Testing and Inspection/Programming and Relearning
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Locations
Fuel Level Sensor: Locations
Powertrain Component Views
Fuel Pump and Sender Assembly
1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
1. Remove the fuel sender assembly. 2. Using two flat-bladed tools, carefully pull both locking tabs
(1) outward while simultaneously lifting the level sensor.
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3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
Installation Procedure
1. Push in the electrical terminals (1) and ensure the terminals are secure.
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2. Carefully insert the level sensor until the locking tabs (1) snap into the locking position. 3. Install
the fuel sender assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Powertrain Component Views
Fuel Tank Components
1 - Fuel Tank 2 - Fuel Pump and Sender Assembly 3 - Fuel Tank Pressure (FTP) Sensor 4 Evaporative Emission (EVAP) Canister Vent Solenoid Valve
Fuel Pump and Sender Assembly
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1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator
- Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
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Component Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Information Bus: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Diagrams > Diagram Information and Instructions > Page 8214
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Diagrams > Diagram Information and Instructions > Page 8215
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Diagrams > Page 8216
Information Bus: Description and Operation
Data Link Communications Description and Operation
Circuit Description
The communication among control modules is performed through the High speed GMLAN serial
data circuits and the Low speed GMLAN serial data circuit. The modules that need real time
communication are attached to the High speed GMLAN network. The body control module (BCM)
is the gateway between the high and low speed networks. Communication is necessary between
the high and low speed serial data modules for the vehicle to start. Refer to Body Control System
Description and Operation for more information about the gateway.
Signal supervision is the process of determining whether an expected signal is being received or
not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If
such a signal is lost, the signal supervision part of the software will set a no communication DTC (U
code) against the missing device. This code is mapped on the Tech 2 screen as a code against the
physical device. A lost communication DTC typically is set in modules other than the module with a
communication failure.
GMLAN High Speed Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN
serial data circuit. The serial data is transmitted on two twisted wires that allow speed up to 500
Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine
control module (ECM) and the other is after the vehicle communication interface module (VCIM).
The VCIM is considered a DLC termination point of the link although it does not contain the resistor
and can be used as a diagnostic point. The high speed GMLAN is a differential bus. The high
speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite
extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered
recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds
one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed
GMLAN serial data bus (-) wire.
GMLAN Low Speed Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial
data circuit. The serial data is transmitted over a single wire to the appropriate control modules.
Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol
produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module
pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low,
0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN
low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage
level of the pulse is +10 volts. Modules connected to the GMLAN low speed buss can be part of a
virtual network as described in GMLAN High Speed Circuit Description above. The modules on the
GMLAN low speed serial data buss are connected to the buss using SP 205 as the common
connection sometimes called a star connector.
Data Link Connector (DLC)
The data link connector (DLC) is a standardized 16-cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Pin 1 GMLAN low speed communications terminal
* Pin 4 Scan tool power ground terminal
* Pin 5 Common signal ground terminal
* Pin 6 High speed GMLAN serial data bus (+) terminal
* Pin 14 High speed GMLAN serial data bus (-) terminal
* Pin 16 Scan tool power, battery positive voltage terminal
Serial Data Reference
The scan tool communicates over the various busses on the vehicle. In order to avert
misdiagnoses of No Communication with a specific module and to determine if a module is low or
high speed, refer to Data Link References for a list of modules, the busses they communicate with,
and the RPO codes for a specific module. See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Data Link References
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Data Communications
Diagnostic Starting Point - Data Communications
Begin the system diagnosis with Diagnostic System Check - Vehicle. The Diagnostic System
Check - Vehicle will provide the following information:
* The identification of the control modules which are not communicating
* The identification of any stored diagnostic trouble codes (DTCs) and their status. See: Testing
and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin
vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.
Data Link References
Data Link References
This table identifies which serial data link that a particular module uses for in-vehicle data
transmission. Some modules may use more than one data link to communicate. Some modules
may have multiple communication circuits passing through them without actively communicating on
that data link. This table is used to assist in correcting a communication malfunction. For the
description and operation of these serial data communication circuits refer to Data Link
Communications Description and Operation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8219
Information Bus: Symptom Related Diagnostic Procedures
Symptoms - Data Communications
Symptoms - Data Communications
Important: The following steps must be completed before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle before using the symptom tables in order to
verify that all of the following are true:
* There are no DTCs set.
* The control modules can communicate via the serial data links. See: Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
2. Review the system operation in order to familiarize yourself with the system functions. Refer to:
* Body Control System Description and Operation
* Data Link Communications Description and Operation
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the systems.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests
and General Diagnostics
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Scan Tool Does Not Power Up
* Scan Tool Does Not Communicate with High Speed GMLAN Device
* Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8220
Circuit/System Description
Modules connected to the high speed GMLAN serial data circuits monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The
high speed GMLAN serial data circuits must be operational for the vehicle to start due to body
control module (BCM) and engine control module (ECM) communications. The vehicle theft
deterrent (VTD) module and ECM exchange information using the BCM as the gateway module
allowing communication between the high and low speed serial data buses. The low speed
GMLAN serial data circuit must also be operational for vehicle starting. The high speed GMLAN
serial data bus uses two 120 ohm terminating resistors that are in parallel with the high speed
GMLAN (+) and (-) circuits. One of the resistors is internal to the ECM and the other is either
behind the left kick panel (w/o UE1) or in the rear compartment (UE1).
Diagnostic Aids
* Communication may be available between the BCM and the scan tool with the high speed
GMLAN serial data system inoperative. This condition is due to the BCM using both the high and
low speed GMLAN systems.
* Use the Data Link References to identify the high speed GMLAN serial data modules.
* This test is used for a total high speed GMLAN communication failure. If only 1 module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate.
* The engine will not start when there is a total malfunction of the high speed GMLAN serial data
bus. The following conditions may cause a total loss of high speed GMLAN data communication:
- A short between high speed GMLAN (+) and high speed GMLAN (-) circuits
- Any of the high speed GMLAN serial data circuits shorted to ground or voltage
- A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN
circuits
Circuit/System Testing
1. Test for less than 1.0 ohm of resistance between the DLC ground circuit terminal 5 and ground.
^ If greater than the specified range, test the ground circuit for open/high resistance.
2. Remove the terminator resistor. 3. Test for 110-130 ohms of resistance between the terminals of
the resistor.
^ If not within the specified range, replace the resistor.
4. Ignition OFF, disconnect the harness connector X 3 of the BCM. 5. Ignition ON, test for less than
1 volt between the high speed GMLAN serial data circuit of the DLC terminal 6 and ground, and
terminal 14 and
ground.
^ If greater than the specified range, test the serial data circuit for a short to voltage.
6. Test for infinite resistance between the high speed GMLAN serial data circuit of the DLC terminal
6 and ground, and terminal 14 and ground.
^ If less than the specified value, test the serial data circuit for a short to ground.
7. Test for infinite resistance between the high speed GMLAN serial data circuits of the DLC
terminal 6 and 14.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8221
^ If less than the specified value, test the serial data circuits for a short between them.
8. Test for less than 2 ohms of resistance in the GMLAN serial data circuit between the DLC
terminal 6 and BCM terminal 16.
^ If greater than the specified range, test the GMLAN serial data circuit for open/high resistance.
9. Ignition OFF, connect the terminator resistor, and disconnect the harness connector X 4 of the
BCM.
10. Verify a test lamp illuminates between each ground circuit terminal of the BCM listed below and
B+.
* X 3 terminal 1
* X 3 terminal 5
* X 4 terminal 9
^ If the test lamp does not illuminate, test the ground circuit for an open/high resistance.
11. Ignition ON, verify a test lamp illuminates between each B+ circuit terminal of the BCM listed
below and ground.
* X 4 terminal 1
* X 4 terminal 3
* X 4 terminal 4
^ If the test lamp does not illuminate, test the B+ circuit for an open/high resistance or short to
ground.
12. Connect the harness connectors of the BCM. 13. Ignition OFF, disconnect the harness
connector of the ECM as listed:
* RPO LS4 - X3
* RPO LZE, LZ4 or LZ8 - X1
14. Attempt to communicate with the BCM. Communication should not be available.
^ If communication is established, replace the ECM.
15. Ignition OFF, disconnect the harness connector of the TCM. 16. Attempt to communicate with
the BCM. Communication should not be available.
^ If communication is established, test the serial data circuits for a short between the circuits, short
to voltage, or a short to ground between the TCM and the ECM. If the circuits test normal, replace
the TCM.
17. Ignition OFF, disconnect the harness connector of the EBCM, if equipped. Attempt to
communicate with the BCM. Communication should not be
available.
^ If communication is established, test the serial data circuits for a short between the circuits, short
to voltage, or a short to ground between the EBCM and the TCM. If the circuits test normal, replace
the EBCM.
18. Ignition OFF, disconnect the harness connector X3 of the BCM. 19. Ignition ON, test for less
than 1 volt between the serial data circuits of BCM terminal 8 and ground, and between BCM
terminal 9 and ground.
^ If greater than the specified range, test the circuit for a short to voltage.
20. Test for infinite resistance between the serial data circuits of BCM terminal 8 and ground, and
between BCM terminal 9 and ground.
^ If less than the specified value, test the circuit for a short to ground.
21. Test for infinite resistance between the serial data circuits of BCM terminal 8 terminal 9.
^ If less than the specified value, test the serial data circuits for a short between them.
22. If the circuits test normal, replace the BCM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8222
* GMLAN Wiring Repairs.
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
Modules connected to the low speed GMLAN serial data circuit monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The low
speed GMLAN serial data circuit must be operational for the vehicle to start so the vehicle theft
deterrent (VTD) module and body control module (BCM) can communicate. The low speed GMLAN
serial data circuit uses JX205 as the common connection between the modules and the data link
connector (DLC).
Diagnostic Aids
* Use the Data Link References to identify the low speed GMLAN serial data modules.
* This test is used for a total low speed GMLAN communication failure. If only 1 module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the low speed GMLAN serial data circuit between the splice pack and a module will
only effect the specific module. This type of failure will set a loss of communication DTC for the
module effected, and the other modules will still communicate.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate. The vehicle modules will still communicate, and the vehicle
will start.
* An open between the DLC and JX205 will only effect the communication with the scan tool. The
vehicle modules will still communicate, and the vehicle will start.
* The engine will not start when there is a total malfunction of the low speed GMLAN serial data
circuit. The following conditions may cause a total loss of low speed GMLAN data communication:
- The low speed GMLAN serial data circuit shorted to ground or voltage.
- A module internal malfunction that causes a short to voltage or ground on the low speed GMLAN
circuit.
Circuit/System Testing
Low Speed GMLAN Initial Test
1. Test for less than 1 ohm of resistance between the DLC ground circuit terminal 5 and ground.
^ If greater than the specified range, test the ground circuit for open/high resistance.
2. Ignition OFF, disconnect the harness connector (splice pack comb) at JX205. Test for infinite
resistance between the following JX205 serial data
circuit terminals and ground.
* Terminal A
* Terminal B
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8223
^ If less than the specified value, test the serial data circuit for a short to ground.
3. Test for less than 0.1 volt between the following JX205 serial data circuit terminals and ground.
* Terminal A
* Terminal B
^ If greater than the specified range, test the serial data circuit for a short to voltage.
4. Test for less than 1 ohm of resistance on the serial data circuit between terminal A of JX205 and
terminal 1 of the DLC.
^ If greater than the specified range, test the serial data circuit for open/high resistance.
5. Ignition OFF, install a 3-amp fused jumper wire between terminal A and terminal F of JX205.
Attempt to communicate with the inflatable restraint
sensing and diagnostic module (SDM). Communication should be available.
^ If no communication is established, refer to SDM Serial Data Circuit Test.
Important: After each connection, cycle the ignition key off for 5 seconds, then ON before
attempting to establish communication.
6. Ignition OFF, with the jumper wire still attached to terminal A, individually move the other end of
the jumper wire to each of the terminals listed
below and attempt to communicate with the applicable module. Communications should be
available with each module listed.
* Terminal D, radio
* Terminal G, instrument panel cluster (IPC)
* Terminal H, remote control door lock receiver (RCDLR)
* Terminal K, TDM
* Terminal L, HVAC control module
* Terminal M, BCM
^ If any module does not communicate, test the serial data circuit between the applicable module
harness connector and the JX205 harness connector for a short to ground or a short to voltage. If
the circuit tests normal, replace the applicable module.
SDM Serial Data Circuit Test
Important: Ensure a 3-amp fused jumper wire is installed between terminal A and terminal F of
JX205.
1. Ignition OFF, disconnect the harness connector of the inflatable restraint passenger presence
system (PPS) module. Attempt to communicate with
the SDM. Communication should not be available.
^ If communication is established, replace the PPS module.
2. Ignition OFF, disconnect harness connector X3 at the heated seat control module if equipped
(KA1). Attempt to communicate with the SDM.
Communication should not be available.
^ If communication is established, replace the heated seat control module.
3. Ignition OFF, disconnect harness connector X1 at the vehicle communication interface module
(VCIM) if equipped (UE1). Attempt to
communicate with the SDM. Communication should not be available.
^ If communication is established, replace the VCIM.
4. Ignition OFF, disconnect the harness connector at the Digital radio receiver (DRR) if equipped
(U2K). Attempt to communicate with the SDM.
Communication should not be available.
^ If communication is established, replace the DRR.
5. Ignition OFF, disconnect the harness connector at the SDM. Test for infinite resistance between
the following SDM serial data circuit terminals
and ground.
* Terminal 2
* Terminal 3
^ If less than the specified value, test the serial data circuit for a short to ground.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8224
6. Ignition ON, test for less than 0.1 volt between the following SDM serial data circuit terminals
and ground.
* Terminal 2
* Terminal 3
^ If greater than the specified range, test the serial data circuit for a short to voltage.
7. If the circuits test normal, replace the SDM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
* GMLAN Wiring Repairs.
Scan Tool Does Not Power Up
Scan Tool Does Not Power Up
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The data link connector (DLC) is a standardized 16 cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Scan tool B+ voltage at terminal 16
* Scan tool ground at terminal 4
* Common ground at terminal 5
Diagnostic Aids
* The scan tool will power up with the ignition OFF. Some modules however, will not communicate
unless the ignition is ON and the power mode master (PMM) module sends the appropriate power
mode message.
* If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the
malfunction must be due to the scan tool/CANdi module.
Circuit/System Testing
1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and
terminal 5 of the DLC and ground.
^ If greater than the specified range, test the ground circuit for an open/high resistance.
2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and
ground.
^ If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an
open/high resistance.
3. If all circuits test normal, refer to the scan tool/CANdi module user guide.
Repair Instructions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8225
Perform the Diagnostic Repair Verification after completing the repair. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 8229
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8301
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8302
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Information > Diagrams > Diagram Information and Instructions > Page 8303
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8304
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8305
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8306
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8307
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8308
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8309
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8310
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8311
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8312
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8313
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8314
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8315
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8316
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8317
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8318
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8319
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8320
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8321
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 8323
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8324
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8325
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Information > Diagrams > Diagram Information and Instructions > Page 8326
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Information > Diagrams > Diagram Information and Instructions > Page 8327
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8328
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 8329
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8330
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8331
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8333
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8334
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 8351
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8352
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8353
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8354
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8355
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8356
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8357
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8358
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8359
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8360
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 8361
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 8362
Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 8363
5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 8364
2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 8365
6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 8369
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 8370
^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code
Descriptions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
^ If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
^ If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM.
^ If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
* Instrument Cluster Replacement (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Top of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 8377
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1 15 - Fuel Injector 2 16 - Ignition
Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 8378
20 - Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 8379
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 8380
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor
electrical connector (2).
3. Remove the MAP sensor (714) from the intake manifold. 4. Remove the MAP sensor grommet
(715), if required.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 8381
1. Lubricate the MAP sensor grommet with clean engine oil, if required. 2. Install the MAP sensor
grommet (715), if required. 3. Install the MAP sensor (714).
4. Connect the MAP sensor electrical connector (2). 5. Install the engine sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Locations
Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Locations > Page 8385
15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Locations > Page 8386
Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Locations > Page 8387
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Locations > Page 8388
1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace
Post-Catalyst O2 Sensor
Oxygen Sensor: Recalls Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace
Post-Catalyst O2 Sensor > Page 8397
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > Recalls: > 07178 > Jul > 07 > Campaign - Inspect/Replace
Post-Catalyst O2 Sensor > Page 8398
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07178 > Jul > 07 > Campaign Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: All Technical Service Bulletins Campaign - Inspect/Replace Post-Catalyst O2
Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07178 > Jul > 07 > Campaign Inspect/Replace Post-Catalyst O2 Sensor > Page 8404
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
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Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-08-44-008A >
Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting
Radio Receiver: All Technical Service Bulletins Audio System - XM Radio(R) Won't Retain Station
Setting
TECHNICAL
Bulletin No.: 08-08-44-008A
Date: April 25, 2008
Subject: XM Radio Does Not Retain Station Setting From Previous Key Cycle and Changes To
Channel 1, The Preview Channel, at Vehicle Start-up (Replace Digital Radio Receiver Assembly)
Models: 2008 Buick Enclave, Lucerne 2008 Cadillac DTS, Escalade Models, SRX 2008 Chevrolet
Avalanche, Equinox, Impala, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia 2008 GMC
Sierra, Yukon Models 2008 Pontiac Torrent 2008 HUMMER H2, H2 SUT 2007-2008 Saturn
OUTLOOK 2008 Saturn VUE 2008 Suzuki XL-7
with XM Satellite Radio (RPO U2K)
Supercede:
This bulletin is being revised to add the Suzuki XL-7 model. Please discard Corporate Bulletin
Number 08-08-44-008 (Section 08 - Body & Accessories).
Condition
Some customers may comment that the XM radio does not retain the station setting from the
previous key cycle and changes to channel 1 at vehicle start-up. After start-up, the XM radio will be
on the preview channel 1.
Cause
A software anomaly in the Digital Radio Receiver Assembly may cause this condition.
Correction
Technicians are to replace the Digital Radio Receiver Assembly with an updated design part. Refer
to the Digital Radio Receiver Replacement procedure in SI. Also refer to the Digital Radio Receiver
Setup procedure in SI for additional information.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-08-44-008A >
Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting > Page 8411
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-08-44-008A >
Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting > Page 8417
For vehicles repaired under warranty, use the table.
Disclaimer
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Component Information > Technical Service Bulletins > Page 8418
Oxygen Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Underbody
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1 - Heated Oxygen Sensor (HO2S) 2
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Component Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Component Information > Diagrams > Diagram Information and Instructions > Page 8426
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Component Information > Diagrams > Diagram Information and Instructions > Page 8429
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Component Information > Diagrams > Diagram Information and Instructions > Page 8431
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Component Information > Diagrams > Diagram Information and Instructions > Page 8433
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Component Information > Diagrams > Diagram Information and Instructions > Page 8449
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 8452
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Component Information > Diagrams > Diagram Information and Instructions > Page 8454
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 8509
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 8544
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 8548
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Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LS4)
Heated Oxygen Sensor (HO2S) 2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 8550
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 8553
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 8554
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 8555
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 8556
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 8557
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Remove the intake manifold sight shield. 2. Remove the connector position assurance (CPA)
retainer (1). 3. Disconnect the bank 1 sensor 1 electrical connector (2).
4. Remove the bank 1 sensor 1 from the exhaust manifold.
Installation Procedure
Important: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before reinstallation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 8560
1. If re-installing the old sensor, coat the threads with anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 1 sensor 1 to the exhaust manifold.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 1 sensor 1 electrical connector (2). 4. Install the CPA retainer (1). 5. Install the
intake manifold sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 8561
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position
assurance (CPA) retainer. 3. Disconnect the bank 2 sensor 2 electrical connector.
4. Remove the bank 2 sensor 2 from the catalytic converter.
Installation Procedure
Important: A special anti-seize compound is use on the heated oxygen sensor (HO2S) threads.
The compound consists of liquid graphite and glass beads. The graphite tends to burns away, but
the glass beads remain, making the sensor easier to remove. New or service replacement sensors
already have the compound applied to the threads. If the sensor is removed from an exhaust
component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize
compound applied before reinstallation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 8562
1. If re-installing the old sensor, coat the threads with the anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 2 sensor 2 to the catalytic converter.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 2 sensor 2 electrical connector. 4. Install the CPA retainer. 5. Lower the
vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Unable To Reprogram Body Control Module > Page 8568
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Unable To Reprogram Body Control Module > Page 8569
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Unable To Reprogram Body Control Module > Page 8570
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8571
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Near the Steering Column
1 - Instrument Panel Carrier 2 - Inflatable Restraint Steering Wheel Module 3 - Steering Column 4 Body Control Module (BCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8572
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8573
Body Control Module (BCM) X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8574
Body Control Module (BCM) X3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8575
Body Control Module (BCM) X4
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8576
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8577
Body Control Module (BCM) X5
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8578
Body Control Module (BCM) X6
Body Control Module (BCM) X7
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8579
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
8580
Body Control Module: Service and Repair
Body Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8585
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8586
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8587
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8588
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8589
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8590
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8591
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8592
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage > Page 8593
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Front of Vehicle/Engine
Compartment Component Views
Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Front of Vehicle/Engine
Compartment Component Views > Page 8596
Engine Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
Engine Control Module: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8599
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8600
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8601
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8602
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8603
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8604
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8605
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8606
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8607
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8608
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8609
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8610
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8611
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8612
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8613
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8614
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8615
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8616
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and Instructions > Page 8617
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8618
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8619
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8620
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8621
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8622
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and Instructions > Page 8623
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and Instructions > Page 8624
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 8625
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and Instructions > Page 8626
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 8627
Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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and Instructions > Page 8669
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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and Instructions > Page 8672
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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and Instructions > Page 8673
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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and Instructions > Page 8675
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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and Instructions > Page 8678
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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and Instructions > Page 8679
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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and Instructions > Page 8680
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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and Instructions > Page 8681
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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and Instructions > Page 8682
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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and Instructions > Page 8683
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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and Instructions > Page 8684
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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and Instructions > Page 8689
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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and Instructions > Page 8692
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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and Instructions > Page 8704
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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and Instructions > Page 8706
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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and Instructions > Page 8710
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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and Instructions > Page 8717
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 8721
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 8724
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and Instructions > Page 8726
Engine Control Module: Connector Views
Component Connector End Views
Engine Control Module (ECM) X1 (LS4)
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Engine Control Module (ECM) X2 (LS4)
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Engine Control Module (ECM) X2 (LS4) (Pin 1 To 33)
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Engine Control Module (ECM) X2 (LS4) (Pin 34 To 73)
Engine Control Module (ECM) X3 (LS4)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for ECM replacement, inspect the ECM first to see if the replacement is
the correct part. If the ECM is faulty, remove the ECM and install the new service ECM.
The new service ECM will not be programmed. You must program the new ECM. DTC P0602
indicates the EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch
the connector pins or the soldered components on the circuit board.
Notice: Always turn the ignition off when installing or removing the ECM connectors in order to
prevent damage to the components.
Removal Procedure
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life, if required. 2. Disconnect the negative battery cable. 3. Remove the left front inner fender
brace. 4. Remove the air cleaner assembly. 5. Disconnect the ECM electrical connectors (2).
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6. Remove the ECM from the air cleaner lower housing.
Installation Procedure
1. Install the ECM to the air cleaner lower housing.
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2. Connect the ECM electrical connectors (2). 3. Install the air cleaner assembly. 4. Install the left
front inner fender brace. 5. Connect the negative battery cable. 6. Program the new ECM. See:
Testing and Inspection/Programming and Relearning
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
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^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code
Descriptions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
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Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
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1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Powertrain Component
Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Instructions > Page 8873
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 8874
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 8875
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Instructions > Page 8879
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Instructions > Page 8880
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 8881
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 8882
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Instructions > Page 8883
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Powertrain Component
Views > Page 8890
Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
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Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
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Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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and Instructions > Page 8956
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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and Instructions > Page 8957
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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and Instructions > Page 8958
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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and Instructions > Page 8961
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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and Instructions > Page 8962
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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and Instructions > Page 8967
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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and Instructions > Page 8969
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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and Instructions > Page 9013
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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and Instructions > Page 9015
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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and Instructions > Page 9017
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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and Instructions > Page 9018
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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and Instructions > Page 9019
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 9023
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 9024
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 9025
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and Instructions > Page 9026
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON
P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9037
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9038
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9039
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A
> Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9040
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9046
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9047
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9048
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): >
10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 9049
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Page 9050
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Page 9051
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Page 9052
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer
to Cooling System Draining and Filling (9C1, 9C3
Static Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) Cooling
System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the ECT sensor electrical connector (1).
3. Remove the ECT sensor.
Installation Procedure
Notice: Replacement components must be the correct part number for the application. Components
requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are
identified in the service procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified. These coatings can
affect the final torque, which may affect the operation of the component. Use the correct torque
specification when installing components in order to avoid damage.
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Page 9053
1. Coat the thread of the ECT sensor with sealer GM P/N 12346004 (Canadian P/N 10953480), or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the ECT sensor.
Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (1). 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9059
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9060
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9061
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9062
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9063
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9064
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9065
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9066
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9067
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9068
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9069
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 9070
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 9186
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
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Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Crankshaft Position Sensor Replacement > Page 9190
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic
Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/P Code Charts/P0315 See: Testing and Inspection/Diagnostic Trouble
Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
Powertrain Component Views
Fuel Pump and Sender Assembly
1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Fuel Level Sensor: Service and Repair
Fuel Level Sensor Replacement
Removal Procedure
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
1. Remove the fuel sender assembly. 2. Using two flat-bladed tools, carefully pull both locking tabs
(1) outward while simultaneously lifting the level sensor.
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3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
Installation Procedure
1. Push in the electrical terminals (1) and ensure the terminals are secure.
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2. Carefully insert the level sensor until the locking tabs (1) snap into the locking position. 3. Install
the fuel sender assembly.
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Fuel Tank Pressure Sensor: Locations
Powertrain Component Views
Fuel Tank Components
1 - Fuel Tank 2 - Fuel Pump and Sender Assembly 3 - Fuel Tank Pressure (FTP) Sensor 4 Evaporative Emission (EVAP) Canister Vent Solenoid Valve
Fuel Pump and Sender Assembly
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1 - Fuel Line Quick Connector 2 - Fuel Pump 3 - Base Plate 4 - Fuel Strainer 5 - Fuel Level Sensor
6 - Springs 7 - Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Powertrain
Component Views
Intake Air Temperature Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Component Views > Page 9209
Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
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Intake Air Temperature Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Instructions
Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9306
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 9350
5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 9351
2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 9352
6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Top of Engine (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 9356
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1 15 - Fuel Injector 2 16 - Ignition
Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 9357
20 - Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 9358
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 9359
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor
electrical connector (2).
3. Remove the MAP sensor (714) from the intake manifold. 4. Remove the MAP sensor grommet
(715), if required.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 9360
1. Lubricate the MAP sensor grommet with clean engine oil, if required. 2. Install the MAP sensor
grommet (715), if required. 3. Install the MAP sensor (714).
4. Connect the MAP sensor electrical connector (2). 5. Install the engine sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations
Oil Pressure Sensor: Locations
Powertrain Component Views
Top of Engine (LS4)
Top Of Engine
1 - Ignition Coil 8 2 - Fuel Injector 8 3 - Evaporative Emission (EVAP) Canister Purge Solenoid
Valve 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Engine Oil Pressure
(EOP) Sensor 7 - Fuel Injector 7 8 - Ignition Coil 7 9 - Fuel Injector 5 10 - Ignition Coil 5 11 - Fuel
Injector 3 12 - Ignition Coil 3 13 - Fuel Injector 1 14 - Ignition Coil 1
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 9364
15 - Fuel Injector 2 16 - Ignition Coil 2 17 - Fuel Injector 4 18 - Ignition Coil 4 19 - Fuel Injector 6 20
- Ignition Coil 6
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 9365
Oil Pressure Sensor: Diagrams
Component Connector End Views
Engine Oil Pressure (EOP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 9366
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Tools Required
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
2. Disconnect the oil pressure sensor electrical connector (4).
3. Using J 41712 , remove the oil pressure sensor (706) and washer (707).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 9367
1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants,
and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
2. Using J 41712 , install the oil pressure sensor (706) and washer (707).
Tighten the sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (4). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: All Technical Service Bulletins Campaign - Inspect/Replace Post-Catalyst O2
Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 9376
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 9377
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: >
07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Oxygen Sensor: Recalls Campaign - Inspect/Replace Post-Catalyst O2 Sensor
Subject: Service Update for Inventory Vehicles Only-Post Catalyst Oxygen (02) Sensor Inspect/Replace - Expires September 30, 2007 # 07178 - (07/09/2007)
Models: 2007 Chevrolet Impala, Monte Carlo 2008 Chevrolet Impala
THIS SERVICE UPDATE INVOLVED VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE SEPTEMBER 30, 2007.
Purpose
This bulletin provides a service procedure to inspect and, if necessary, replace the Post Catalyst
Oxygen (02) Sensor on certain 2007 Chevrolet Impala, Monte Carlo; and 2008 Chevrolet Impala
vehicles.
These vehicles may have been built with an incorrect Post Catalyst Oxygen (02) Sensor.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than September 30, 2007 at which time this bulletin will expire.
Vehicles Involved
Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts.
Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency
situation, parts should be ordered on a CSO = Customer Special Order.
Important:
It is estimated that after Inspection less than 1% of involved vehicles will require a Post Catalyst
Oxygen (02) Sensor replacement. Parts should only be ordered when the Inspection determines
that it is necessary to replace the Post Catalyst Oxygen (02) Sensor.
Service Procedure
Post Catalyst 02 Sensor Inspection and Replacement Procedure
Important:
2007 model year Chevrolet vehicles should be equipped with the "Delphi" brand, P/N 12570149,
Post Catalyst Oxygen (02) Sensor. 2008 model year Chevrolet vehicles should be equipped with
the "Denso" brand, P/N 12608662, Post Catalyst Oxygen (02) Sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: >
07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 9383
1. Raise and support the vehicle.
2. Inspect the heated oxygen sensor bank 1 sensor 2 by pulling back the oxygen sensor protective
sleeve (1). The wires should be the following colors:
- Delphi P/N 12570149 - Used on Model Year 2007, Brown (2), Purple (1) and Tan (1).
- Denso P/N 12608662 - Used on Model Year 2008, Black (2), White (1), and Blue (1).
3. If the inspection identifies that the vehicle was built with the incorrect sensor, replace bank 1
sensor 2 with the correct sensor as mentioned above. Refer to step 5 for the sensor replacement
procedure, if necessary.
4. If the vehicle was built with the correct sensor, ensure that the protective sleeve is restored to its
original position and lower the vehicle.
5. Remove the connector position assurance (CPA) retainer.
6. Disconnect the bank 1 sensor 2 electrical connector.
7. Remove the sensor from the catalytic converter.
8. Install the correct sensor as mentioned above to the catalytic converter.
Tighten
Tighten the sensor to 42 N.m (31 lb-ft).
9. Connect the bank 1 sensor 2 electrical connector.
10. Install the CPA retainer.
11. Lower the vehicle.
Claim Information
For vehicles repaired under this service update, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: >
07178 > Jul > 07 > Campaign - Inspect/Replace Post-Catalyst O2 Sensor > Page 9384
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Oxygen Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up
TECHNICAL
Bulletin No.: 10-06-01-007C
Date: February 09, 2011
Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine
Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters)
Models:
2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac
Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with
AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV,
Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet
Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet
Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with
AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4,
LY5 or LZ1
Attention:
This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM
Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please
refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI.
Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number
10-06-01-007B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on an engine valve lifter tick noise that occurs after the engine has
been shut off for at least two hours. The tick noise may last from two seconds to ten minutes.
Cause
This condition may be caused by any of the following:
- Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly.
- A low engine oil level or incorrect oil viscosity.
- Dirty or contaminated oil.
- A low internal valve lifter oil reservoir level.
- Debris in the valve lifter.
- A high valve lifter leak down rate.
Correction
If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is
noted during the concern, perform the following steps:
1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance
Care > Checking Things Under the Hood >
Description and Operation > Engine Oil in SI.
‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor
quality/contamination is observed, change the oil
and filter.
Note
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Oxygen Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page
9390
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Oxygen Sensor: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page
9396
Allow at least a two hour soak time between engine OFF and start up when evaluating the tick
noise.
2. Start the engine and evaluate the valve lifter tick noise.
‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter
Replacement in SI.
Parts Information
Note
A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 9397
Oxygen Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
Underbody
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 9398
1 - Heated Oxygen Sensor (HO2S) 2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Oxygen Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9401
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9402
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9403
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9404
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9405
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9406
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9407
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9408
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9409
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9410
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9411
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9412
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9413
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9415
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9416
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9417
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9418
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9419
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9420
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9421
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9422
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9423
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 9519
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9520
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9521
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9522
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9523
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9524
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9525
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 9526
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9527
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 9528
Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LS4)
Heated Oxygen Sensor (HO2S) 2
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Instructions > Page 9529
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice > Page 9532
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen Sensor Notice > Page 9533
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice > Page 9534
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice > Page 9535
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Oxygen Sensor Notice > Page 9536
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Remove the intake manifold sight shield. 2. Remove the connector position assurance (CPA)
retainer (1). 3. Disconnect the bank 1 sensor 1 electrical connector (2).
4. Remove the bank 1 sensor 1 from the exhaust manifold.
Installation Procedure
Important: A special anti-seize compound is used on the HO2S threads. The compound consists of
liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain,
making the sensor easier to remove. New or service replacement sensors already have the
compound applied to the threads. If the sensor is removed from an exhaust component and if for
any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before reinstallation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 9539
1. If re-installing the old sensor, coat the threads with anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 1 sensor 1 to the exhaust manifold.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 1 sensor 1 electrical connector (2). 4. Install the CPA retainer (1). 5. Install the
intake manifold sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 9540
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
Removal Procedure
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position
assurance (CPA) retainer. 3. Disconnect the bank 2 sensor 2 electrical connector.
4. Remove the bank 2 sensor 2 from the catalytic converter.
Installation Procedure
Important: A special anti-seize compound is use on the heated oxygen sensor (HO2S) threads.
The compound consists of liquid graphite and glass beads. The graphite tends to burns away, but
the glass beads remain, making the sensor easier to remove. New or service replacement sensors
already have the compound applied to the threads. If the sensor is removed from an exhaust
component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize
compound applied before reinstallation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 > Page 9541
1. If re-installing the old sensor, coat the threads with the anti-seize compound P/N 12377953, or
equivalent.
Notice: Refer to Fastener Notice.
2. Install the bank 2 sensor 2 to the catalytic converter.
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the bank 2 sensor 2 electrical connector. 4. Install the CPA retainer. 5. Lower the
vehicle.
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Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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and Instructions > Page 9606
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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and Instructions > Page 9608
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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and Instructions > Page 9609
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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and Instructions > Page 9622
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and Instructions > Page 9663
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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and Instructions > Page 9664
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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and Instructions > Page 9666
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 9668
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 9671
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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and Instructions > Page 9672
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > 4T65-E - Automatic
Transaxle
Vehicle Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > 4T65-E - Automatic
Transaxle > Page 9677
Vehicle Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
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Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair
).
3. Disconnect the vehicle speed sensor (VSS) electrical connector.
4. Remove the VSS bolt (9). 5. Remove the VSS (10) from the extension case.
6. Remove the O-ring (11) from the VSS (10).
Installation Procedure
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1. Install the O-ring (11) to the VSS (10).
2. Install the VSS (10).
Notice: Refer to Fastener Notice .
3. Install the VSS bolt (9).
Tighten the bolt (9) to 12 N.m (106 lb in).
4. Connect the VSS electrical connector. 5. Install the right front tire and wheel. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6.
Lower the vehicle.
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Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Component Information > Diagrams > Diagram Information and Instructions > Page 9685
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Locations
Valve Deactivation Solenoid: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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> Component Information > Diagrams > Diagram Information and Instructions
Valve Deactivation Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Valve Deactivation Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9859
1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9860
3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9861
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9862
7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9863
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9864
4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9865
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9866
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9867
6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9868
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9869
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9871
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9872
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9875
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9876
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9877
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9879
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9880
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9881
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9884
7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9886
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9887
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9888
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9889
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9890
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9891
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9892
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9893
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9894
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9895
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9896
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9897
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9898
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9899
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9900
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9901
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9902
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9903
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9904
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9905
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9906
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9907
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9908
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9909
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9910
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9911
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9912
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9913
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9914
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9915
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9916
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9917
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9918
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9919
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9920
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9921
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9922
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9923
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9925
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9926
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9927
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9928
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9929
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9930
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9931
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9933
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9935
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9936
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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> Component Information > Diagrams > Diagram Information and Instructions > Page 9937
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9938
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9939
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9940
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9941
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9942
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9943
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 9944
Valve Deactivation Solenoid: Connector Views
Component Connector End Views - Continued
Valve Lifter Oil Manifold (VLOM) Assembly (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Page 9945
Valve Deactivation Solenoid: Description and Operation
Cylinder Deactivation (Active Fuel Management) System Description
To provide maximum fuel economy under light load driving conditions, the engine control module
(ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1 and 7 on
the left bank, and cylinders 4 and 6 on the right bank, switching to a V4 mode. The engine will
operate on 8 cylinders, or V8 mode, during engine starting, engine idling, and medium to heavy
throttle applications.
When commanded ON, the ECM will determine what cylinder is firing, and begin deactivation on
the next closest deactivated cylinder in firing order sequence. The Gen IV engine has a firing order
of 1-8-7-2-6-5-4-3. If cylinder number 1 is on its combustion event when cylinder deactivation is
commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder
number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is
commanded ON, then the next cylinder in the firing order sequence that can be deactivated is
cylinder number 4.
Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the
selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded
locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing
contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing
contacts the camshaft lobe through a roller. During V8 mode, the locking pins are pushed outward
by spring force, locking the pin housing and outer housing together causing the lifter to function as
a normal lifter. When V4 mode is commanded ON, the locking pins are pushed inward with engine
oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter
pin housing is unlocked from the outer housing, the internal pin housing will remain stationary,
while the outer housing will move with the profile of the camshaft lobe, which results in the valve
remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each
deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter
bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking
pins used for cylinder deactivation.
Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM,
the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation
is timed so that the cylinder is on an intake event. During an intake event, the intake cam lobe is
pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The
force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them
from moving until the intake valve has closed. When the intake valve lifter reaches the base circle
of the camshaft lobe, the valve spring force is reduced, allowing the locking pins to move,
deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust
valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve
lifter to move immediately, and deactivate the exhaust valve.
By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge or exhaust
gas charge in the combustion chamber. The capture of exhaust gases in the combustion chamber
will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions
when operating in V4 mode. During the transition from V8 to V4 mode, the fuel injectors will be
turned OFF on the deactivated cylinders. The ignition system secondary voltage or spark is still
present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are
met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder
deactivation to a cycle time of 10 minutes in V4 mode, and then return to V8 mode for 1 minute.
Switching between V8 and V4 mode is accomplished in less than 250 milliseconds, making the
transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the
time for the ECM to sequence the transitions, the response time for the VLOM solenoids to
energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine
crankshaft.
The cylinder deactivation system consists of the following components:
* The VLOM assembly
* Eight special valve lifters, 2 per deactivating cylinder
* The engine oil pressure regulator valve for cylinder deactivation operation
* Gen IV cylinder deactivation engine block
* The ECM
Valve Lifter Oil Manifold (VLOM) Assembly
The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil
manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake
manifold assembly. The VLOM consists of 4 electrically operated Normally Closed Solenoids. Each
solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the
cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from a
passage on the rear of the cylinder block.
All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the
powertrain relay. The ground or control circuit for each solenoid is connected to the engine control
module (ECM).
When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid
control circuit in firing order sequence, allowing current to flow through the solenoid windings. With
the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the
VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per
cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When
vehicle-operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit
for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil
pressure in the control ports is exhausted through the body of the
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Page 9946
solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds
in the oil passages to purge any air trapped in the VLOM or engine block.
To control any contamination to the hydraulic circuits, a small replaceable oil screen is located in
the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire
sensor which provides oil pressure information to the ECM.
During service, use extreme care in keeping the VLOM assembly free of any contamination or
foreign material.
Engine Control Module (ECM)
The engine control module (ECM) is responsible for the management and control of all engine
functions. Each ECM comes equipped with a specific set of software/calibrations designed for that
engine and vehicle application. The ECM will determine engine operating parameters, based upon
information from a network of switches, sensors, modules and communication with other controllers
located throughout vehicle. Internal to the ECM is an integrated circuit device called a low-side
driver. The low-side driver is designed to operate internally, like an electronic switch. An individual
low-side driver controls each valve lifter oil manifold (VLOM) solenoid. When enabling conditions
for V4 mode are met, the ECM will command the low-side driver to ground each VLOM solenoid
control circuit, in firing order sequence. Internal to the low-side driver is a fault detection circuit,
which monitors the solenoid control circuit for an incorrect voltage level. If an incorrect voltage
level, such as an open, high resistance, or short to ground, is detected, the low-side driver, along
with the fault detection circuit, will communicate the condition to the central processor in the ECM.
The ECM will then command a return to V8 mode, set a corresponding DTC, and illuminate the
malfunction indicator lamp (MIL) on the instrument panel.
Cylinder Deactivation Inhibit Reasons
Listed below are the powertrain conditions that will inhibit V4 mode, while operating under light load
driving conditions:
* Engine manifold vacuum low
* Brake booster vacuum pressure low
* Accelerator pedal position rate of increase too high, electronic throttle control
* Accelerator pedal position too high, electronic throttle control
* Ignition voltage out of range
* Engine oil pressure out of range
* Engine oil temperature out of range
* Engine RPM out of range
* Transmission gear incorrect
* Transmission range incorrect
* Transmission gear shift in progress
* All cylinders activated via scan tool output control
* Minimum time in V8 mode not met
* Maximum V4 mode time exceeded
* Engine oil aeration present
* Decel fuel cutoff active
* Fuel shut-off timer active
* Minimum heater temp low, HVAC system
* Reduced engine power active, electronic throttle control
* Brake torque management active
* Axle torque limiting active
* Engine metal over temperature protection active
* Catalytic converter over temperature protection active
* Piston protection active, knock detected
* Hot coolant mode active
* Engine over speed protection active
* Fault Active or Fault Pending-cylinder deactivation is disabled for the following faults:
- Brake Booster Vacuum Sensor
- Manifold Absolute Pressure Sensor
- Engine Oil Pressure Sensor
- Engine Coolant Temperature Sensor
- Vehicle Speed Sensor
- Crankshaft Position Sensor
- Engine Misfire Detected
- Cylinder Deactivation Solenoid Driver Circuit
The scan tool output control is used to deactivate half of the engine cylinders, V4 mode, by
commanding all of the solenoids ON, or deactivate one cylinder switching to a V7 mode, by
commanding ON one solenoid. Listed below are the powertrain conditions that will inhibit V4 mode,
or V7 mode, with the engine running, while using the scan tool output control function:
* Engine speed out of range
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Page 9947
* Manifold absolute pressure (MAP) sensor fault
* Accelerator pedal position too high, electronic throttle control
* Piston protection active, knock detected
* Engine oil temperature out of range
* Engine oil pressure out of range
* Engine oil aeration present
* Engine metal over temperature protection active
* Accelerator pedal position rate of increase too high, electronic throttle control
* Cylinder deactivation solenoid driver circuit fault
* Engine coolant temperature sensor fault
* Catalytic converter over temperature protection active
* Brake booster vacuum pressure low
* Brake Booster Vacuum Pressure Sensor Fault
* Axle torque limiting active
* Brake torque management active
* Vehicle speed sensor fault
* Engine coolant temperature too high
* Engine not running
* Vehicle speed not zero
* Engine coolant temperature low
* Reduced Engine Power Active, electronic throttle control
* Transmission gear incorrect
* Transmission range incorrect
* Ignition voltage out of range
* Maximum V4 mode time exceeded
Listed below are the powertrain conditions that will inhibit a cylinder deactivation solenoid from
being energized, with the ignition ON and the engine OFF, while using the scan tool output control
function:
* Engine speed not zero
* Vehicle speed not zero
* Transmission not in park or neutral
* Ignition voltage out of range
For the system description covering the hydraulic/mechanical system of cylinder deactivation, refer
to Cylinder Deactivation (Active Fuel Management) System Description.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Page 9948
Valve Deactivation Solenoid: Testing and Inspection
Cylinder Deactivation (Active Fuel Management) System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit Description
To provide maximum fuel economy under light load driving conditions, the engine control module
(ECM) will command the valve lifter oil manifold (VLOM) solenoids ON, to deactivate engine
cylinders 1 and 7 on the left bank, and cylinders 4 and 6 on the right bank. The VLOM consists of 4
electrically operated normally closed solenoids, which directs pressurized engine oil to 8
deactivating valve lifters. All 4 VLOM solenoids are connected in parallel to a fused ignition circuit
supplied by the powertrain relay. The control circuit for each solenoid is connected to an individual
low side driver internal to the ECM. When enabling conditions for V4 mode are met, the ECM will
command each low side driver to turn ON, in engine firing order sequence.
Diagnostic Aids
The VLOM solenoids are assigned to the following engine cylinders:
* Solenoid #1-Cylinder #1
* Solenoid #2-Cylinder #4
* Solenoid #3-Cylinder #6
* Solenoid #4-Cylinder #7
Circuit/System Verification
1. If any DTCs are set, then repair those DTC first. Refer to Diagnostic System Check - Vehicle.
See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic System Check - Vehicle
2. Start and idle the engine. 3. Allow the engine to reach normal engine operating temperature. The
engine should idle smoothly without any misfires. If the engine misfires, refer
to DTC P0300-P0308. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0300
4. Monitor the cylinder deactivation system data parameters with a scan tool. 5. Road test the
vehicle under light throttle and load conditions that will allow the ECM to command V4 mode. If all
enabling conditions are met for
cylinder deactivation, and if no internal engine hydraulic/mechanical fault conditions are present,
the ECM will continue operation in V4 mode.
^ If the vehicle passes the Circuit/System Verification test, then review the active fuel management
driving information in the Features and Controls section of the owners manual with the vehicle
operator, or instruct the vehicle operator in the proper driving techniques to obtain V4 mode.
^ If the vehicle does not pass the Circuit/System Verification test, then review the cylinder
deactivation inhibit reasons listed on the scan tool.
Circuit/System Testing
Electrical System Testing
Ignition ON and the engine OFF, command each VLOM solenoid ON and OFF using the scan tool.
Standing next to the engine compartment, you should be able to hear the solenoid energize and
de-energize with each command.
If you cannot hear each solenoid energize and de-energize, then refer to DTC P3401, P3425,
P3441, or P3449. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P3425
Mechanical System Testing
1. Connect a vacuum gage to the EVAP vacuum tube fitting on the electronic throttle body. DO
NOT use a compound pressure and vacuum gage.
The vacuum gage on a hand held vacuum pump will work fine for this test.
2. Start the engine. Allow the engine to reach normal operation temperature. 3. With a scan tool,
command each VLOM solenoid ON, one at a time. Each time a solenoid is command ON, you
should observe a fluctuating drop
of intake manifold vacuum, and a misfire on the cylinder that was deactivated.
^ If there is no fluctuating drop in engine vacuum, or the engine does not misfire, then refer to
Cylinder Deactivation (Active Fuel Management) System Diagnosis.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid
> Component Information > Diagrams > Page 9949
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > 4T65-E - Automatic Transaxle
Vehicle Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > 4T65-E - Automatic Transaxle > Page 9954
Vehicle Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 9955
Vehicle Speed Sensor: Diagrams
Component Connector End Views
Vehicle Speed Sensor (VSS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 9956
Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair
).
3. Disconnect the vehicle speed sensor (VSS) electrical connector.
4. Remove the VSS bolt (9). 5. Remove the VSS (10) from the extension case.
6. Remove the O-ring (11) from the VSS (10).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations > Page 9957
1. Install the O-ring (11) to the VSS (10).
2. Install the VSS (10).
Notice: Refer to Fastener Notice .
3. Install the VSS bolt (9).
Tighten the bolt (9) to 12 N.m (106 lb in).
4. Connect the VSS electrical connector. 5. Install the right front tire and wheel. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6.
Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Diagrams
Air Injection Pump: Diagrams
Component Connector End Views - Continued
Secondary Air Injection (AIR) Pump (NU3)
Secondary Air Injection (AIR) Pump Solenoid (NU3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Diagrams > Page 9963
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump
Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views - Continued
Secondary Air Injection (AIR) Pump Relay (NU3)
Secondary Air Injection (AIR) Solenoid Relay (NU3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump
Relay > Component Information > Diagrams > Page 9967
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic Converter Replacement See: Service and
Repair 2. Remove the heated oxygen sensor (HO2S) wiring harness from the clips on the catalytic
converter heat shield.
3. Drill out the catalytic converter heat shield rivets. 4. Remove the catalytic converter heat shield.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair > Page 9972
1. Position the catalytic converter heat shield to the underbody. 2. Install NEW catalytic converter
heat shield rivets.
3. Install the HO2S wiring harness from the clips on the catalytic converter heat shield. 4. Install the
catalytic converter. Refer to Catalytic Converter Replacement See: Service and Repair
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams
Canister Purge Solenoid: Diagrams
Component Connector End Views
Evaporative Emission (EVAP) Canister Purge Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 9977
Canister Purge Solenoid: Service and Repair
Evaporative Emission Canister Purge Solenoid Valve Replacement
Removal Procedure
Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to
disconnecting the line in order the avoid possible system contamination.
1. Remove the engine sight shield. 2. Disconnect the EVAP canister purge solenoid electrical
connector (1).
3. Disconnect the EVAP line (2) from the purge solenoid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 9978
4. Disconnect the EVAP canister purge tube from the solenoid.
5. Remove the EVAP canister purge solenoid from the bracket.
Installation Procedure
1. Install the EVAP canister purge solenoid to the bracket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Diagrams > Page 9979
2. Connect the EVAP canister purge tube to the solenoid.
3. Connect the EVAP line (2) to the purge solenoid.
4. Connect the EVAP canister purge solenoid electrical connector (1). 5. Install the engine sight
shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams
Canister Vent Valve: Diagrams
Component Connector End Views
Evaporative Emission (EVAP) Canister Vent Solenoid
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 9984
Canister Vent Valve: Service and Repair
Evaporative Emission Canister Vent Solenoid Valve Replacement
Removal Procedure
Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to
disconnecting the line in order the avoid possible system contamination.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the EVAP canister vent
solenoid valve electrical connector.
3. Disconnect the EVAP canister vent solenoid valve from the EVAP emission canister hose.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 9985
4. Remove the EVAP canister vent solenoid valve bracket bolt. 5. Remove the EVAP canister vent
solenoid valve.
Installation Procedure
1. Install the EVAP canister vent solenoid valve.
Notice: Refer to Fastener Notice.
2. Install the EVAP canister vent solenoid valve bracket bolt.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams > Page 9986
3. Connect the EVAP canister vent solenoid valve to the EVAP emission canister hose.
4. Connect the EVAP canister vent solenoid valve electrical connector. 5. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair
Evaporative Emissions Hose: Service and Repair
Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis
Removal Procedure
Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to
disconnecting the line in order the avoid possible system contamination.
1. Remove the engine sight shield. 2. Remove the air cleaner outlet duct. 3. Remove the brake
master cylinder and reposition. 4. Disconnect the EVAP (2) line from the purge solenoid.
5. Open the fuel/brake pipe retainers (1). 6. Remove the EVAP line from the fuel/brake pipe
retainers (1). 7. Raise and support the vehicle. Refer to Vehicle Lifting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9990
8. Remove the fuel/brake line retainer bolt. 9. Remove the EVAP line from the retainer.
10. Remove the fuel/brake line push in retainer from the underbody. 11. Remove the EVAP line
from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9991
12. Remove the fuel/brake line retainer bolts. 13. Remove the EVAP line from the retainer.
14. Open the fuel/brake line retainer (1). 15. Remove the EVAP line from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9992
16. Disconnect the EVAP (4) line from the fuel tank EVAP line (1). 17. Remove the EVAP line.
Installation Procedure
1. Position the EVAP line. 2. Connect the EVAP (4) line to the fuel tank EVAP line (1).
3. Install the EVAP line to the retainer. 4. Close the fuel/brake line retainer (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9993
5. Install the EVAP line to the retainer.
Notice: Refer to Fastener Notice.
6. Install the fuel/brake line retainer bolts.
Tighten the bolts to 10 N.m (89 lb in).
7. Install the EVAP line to the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9994
8. Install the fuel/brake line push in retainer to the underbody.
9. Install the EVAP line to the retainer.
10. Install the fuel/brake line retainer bolt.
Tighten the bolt to 10 N.m (89 lb in).
11. Lower the vehicle.
12. Install the EVAP line to the fuel/brake pipe retainers (1). 13. Close the fuel/brake pipe retainers
(1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Page 9995
14. Connect the EVAP (2) line to the fuel rail. 15. Position and install the brake master cylinder.
Refer to Master Cylinder Replacement. 16. Install the air cleaner outlet duct. 17. Install the engine
sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation >
System Information > Service Precautions
Exhaust Gas Recirculation: Service Precautions
Exhaust Gas Recirculation (EGR) System Caution
Caution: Avoid breathing fumes and swallowing EGR exhaust deposits when removing
components for cleaning as bodily injury may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair) .
2. If removing the positive crankcase ventilation (PCV) clean air tube perform the following:
1. Remove the PCV clean air tube from the air intake duct. 2. Remove the PCV clean air tube from
the rocker arm cover. 3. Remove the PCV clean air tube.
3. If removing the PCV foul air tube perform the following:
1. Remove the PCV foul air tube from the intake manifold. 2. Remove the PCV foul air tube from
the rocker arm cover. 3. Remove the PCV foul air tube.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 10003
1. If installing the PCV foul air tube perform the following:
1. Install the PCV foul air tube. 2. Install the PCV foul air tube to the rocker arm cover. 3. Install the
PCV foul air tube to the intake manifold.
2. If installing the PCV clean air tube perform the following:
1. Install the PCV clean air tube. 2. Install the PCV clean air tube to the rocker arm cover. 3. Install
the PCV clean air tube to the air intake duct.
3. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See:
Engine, Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission
Control Systems > Air Injection Pump Relay > Component Information > Diagrams
Air Injection Pump Relay: Diagrams
Component Connector End Views - Continued
Secondary Air Injection (AIR) Pump Relay (NU3)
Secondary Air Injection (AIR) Solenoid Relay (NU3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission
Control Systems > Air Injection Pump Relay > Component Information > Diagrams > Page 10008
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)..................................................................................................
..............................................345-414 kPa (50-60 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information > Page 10015
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10018
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10019
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the fuel pump relay when the ignition switch is turned ON. The control
module will disable the fuel pump relay within 2 seconds unless the control module detects ignition
reference pulses. The control module continues to enable the fuel pump relay as long as ignition
reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if
ignition reference pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
*
Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa
(50-60 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10020
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel
rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF
with a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the fuel pump module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Assembly Replacement
* Fuel Injector Replacement
* Fuel Tank Fuel Pump Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 10025
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 10026
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 10027
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Not supplied by manufacturer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 10034
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 10035
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 10036
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
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Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Disconnect the positive crankcase ventilation (PCV) tube from the air inlet duct.
2. Loosen the air inlet duct clamp at the throttle body. 3. Remove the air inlet duct from the throttle
body.
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4. Loosen the air inlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5.
Remove the air inlet duct from the MAF/IAT sensor.
Installation Procedure
1. Install the air inlet duct from the MAF/IAT sensor.
Notice: Refer to Fastener Notice.
2. Tighten the air inlet duct clamp at the MAF/IAT sensor.
Tighten the clamp to 3 N.m (27 lb in).
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3. Install the air inlet duct to the throttle body. 4. Tighten the air inlet duct clamp at the throttle body.
Tighten the clamp to 3 N.m (27 lb in).
5. Connect the PCV tube to the air inlet duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. 2. Release the spring clamps on top of the air cleaner
housing. 3. Remove the air cleaner housing cover. 4. Remove the air filter element.
Installation Procedure
1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Engage the spring
clamps on top of the air cleaner housing. 4. Install the air cleaner outlet duct.
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Component Information > Locations > Powertrain Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
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Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
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Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
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Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10105
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10106
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10108
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10111
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10113
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10157
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10158
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10162
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Component Information > Diagrams > Diagram Information and Instructions > Page 10165
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10168
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10169
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10170
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10171
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10172
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10173
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10174
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10175
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10176
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10177
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 10178
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 10179
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10180
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10181
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 10182
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 10183
1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
INFORMATION
Bulletin No.: 10-06-04-015
Date: December 08, 2010
Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles
Models:
2007-2011 GM Passenger Cars and Trucks
General Motors' position regarding the Environmental Protection Agency announcement allowing
the use of E 15 in 2007 and newer vehicles:
- General Motors' remains focused on securing a safe and positive driving experience for our
customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to
confusion for consumers as to what fuel their vehicle should use. In response, we will continue to
encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The
vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be
used in GM vehicles that do not have a flex fuel designation.
- GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and
these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15
percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However,
ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel
designation as they are not designed and certified to run on gasoline consisting of more than 10
percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual.
- We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce
petroleum dependence and the carbon footprint of driving. As the global leader in producing
vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for
the 2011 model year.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10188
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada)
INFORMATION
Bulletin No.: 05-06-04-022G
Date: October 27, 2010
Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel
Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY
Models:
2011 and Prior GM Passenger Cars and Trucks (Canada Only)
Supercede: This bulletin is being revised to update the model years and include an additional
gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F
(Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate
Bulletin Number 04-06-04-047I.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those
vehicles that have experienced deposit related concerns may especially benefit from use of TOP
TIER Detergent Gasoline.
Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline
Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB
Top Tier Fuel Availability
Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first
national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada
began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began
offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent
Gasoline in May of 2010.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10189
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane
grades :
Chevron Canada (markets in British Columbia and western Alberta)
- Shell Canada (nationally)
- Petro-Canada (nationally)
- Sunoco-Canada (Ontario)
- Esso-Canada (nationally)
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no
metallic additives. It meets new, voluntary deposit control standards developed by six automotive
companies that exceed the detergent recommendations of Canadian standards and does not
contain metallic additives, which can damage vehicle emission control components.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have
already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not
all fuel marketers will offer this product. Once fuel marketers make public announcements, they will
appear on a list of brands that meet the TOP TIER standards.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW,
General Motors, Honda, Toyota, Volkswagen and Audi.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a
detergent additive. However, the requirement is minimal and in many cases, is not sufficient to
keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency
requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any
detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of
detergent is needed than what is required or recommended, and no metallic additives are allowed.
Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency and the intentional addition of metallic additives is an
issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal
fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP
TIER Detergent Gasoline will help reduce deposit related concerns.
Who should use TOP TIER Detergent Gasoline?
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have
experienced deposit related concerns may especially benefit from use of TOP TIER Detergent
Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website,
http://www.toptiergas.com/.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10190
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10191
Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information
INFORMATION
Bulletin No.: 04-06-04-047I
Date: August 17, 2009
Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance,
Stall Concerns) - U.S. Only
Models:
2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010
HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only)
Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier
Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related
concerns may especially benefit from the use of TOP TIER Detergent Gasoline.
Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline
Intake valve: - 10,000 miles with Legal Minimum additive
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent
Gasoline Standards:
- Chevron
- Chevron-Canada
- QuikTrip
- Conoco
Phillips 66
- 76
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10192
- Shell
- Shell-Canada
- Entec Stations located in the greater Montgomery, Alabama area.
- MFA Oil Company located throughout Missouri.
- Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa.
The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky.
Aloha Petroleum
- Tri-Par Oil Company
- Turkey Hill Minit Markets
- Texaco
- Petro-Canada
- Sunoco-Canada
- Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new,
voluntary deposit control standards developed by six automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program
and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements, they will appear
on a list of brands that meet the TOP TIER standards.
Where Can I find the Latest Information on TOP TIER Fuel and Retailers?
On the web, please visit www.toptiergas.com for additional information and updated retailer lists.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi,
BMW, General Motors, Honda, Toyota and Volkswagen.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency is an issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10193
Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions
Bulletin No.: 05-06-04-035C
Date: July 30, 2007
INFORMATION
Subject: Usage of E85 Fuels in GM Vehicles
Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2
2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008
Saab 9-7X
Supercede:
This bulletin is being revised to add the 2008 model year and additional engines with E85
capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System).
Customer Interest in E85 Fuel
As the retail price of gasoline increases, some locations in the country are seeing price differentials
between regular gasoline and E85 where E85 is selling for substantially less than regular grade
gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in
non-E85 compatible vehicles.
Only vehicles designated for use with E85 should use E85 blended fuel.
E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15%
gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10%
ethanol.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
Using E85 Fuels in Non-Compatible Vehicles
General Motors is aware of an increased number of cases where customers have fueled
non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or
with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in
one or more of the following conditions:
Lean Driveability concerns such as hesitations, sags and/or possible stalling.
SES lights due to OBD codes.
Fuel Trim codes P0171 and/or P0174.
Misfire codes (P0300).
Various 02 sensor codes.
Disabled traction control or Stability System disabled messages.
Harsh/Firm transmission shifts.
Fuel system and/or engine mechanical component degradation.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been
fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J
44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with
gasoline - preferably one of the Top Tier brands.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 10194
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at
www.livegreengoyellow.com.
E85 Compatible Vehicles
The only E85 compatible vehicles produced by General Motors are shown.
Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or
www.livegreengoyellow.com are E85 compatible.
All other gasoline and diesel engines are NOT E85 compatible.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Page 10195
Fuel: Specifications
GASOLINE OCTANE
Use premium unleaded gasoline with a posted octane rating of 91 or higher. You may also use
regular unleaded gasoline rated at 87 octane or higher, but your vehicle's acceleration may be
slightly reduced, and you may notice a slight audible knocking noise, commonly referred to as
spark knock. If the octane is less than 87, you may notice a heavy knocking noise when you drive.
If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you
might damage your engine. If you are using gasoline rated at 87 octane or higher and you hear
heavy knocking, your engine needs service.
GASOLINE SPECIFICATIONS
At a minimum, gasoline should meet ASTM specification D 4814 in the United States or
CAN/CGSB-3.5 in Canada. Some gasolines may contain an octane-enhancing additive called
methylcyclopentadienyl manganese tricarbonyl (MMT). General Motors recommends against the
use of gasolines containing MMT.
CALIFORNIA FUEL
If your vehicle is certified to meet California Emissions Standards, it is designed to operate on fuels
that meet California specifications. See the underhood emission control label. If this fuel is not
available in states adopting California emissions standards, your vehicle will operate satisfactorily
on fuels meeting federal specifications, but emission control system performance may be affected.
The malfunction indicator lamp may turn on and your vehicle may fail a smog-check test. If it is
determined that the condition is caused by the type of fuel used, repairs may not be covered by
your warranty.
GASOLINE ADDITIVES
To provide cleaner air, all gasolines in the United States are now required to contain additives that
will help prevent engine and fuel system deposits from forming, allowing your emission control
system to work properly. In most cases, you should not have to add anything to your fuel. However,
some gasolines contain only the minimum amount of additive required to meet U.S. Environmental
Protection Agency regulations. To help keep fuel injectors and intake valves clean, or if your
vehicle experiences problems due to dirty injectors or valves, look for gasoline that is advertised as
TOP TIER Detergent Gasoline.
Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be
available in your area. General Motors recommends that you use these gasolines if they comply
with the specifications described earlier. However, E85 (85% ethanol) and other fuels containing
more than 10% ethanol must not be used in vehicles that were not designed for those fuels.
Notice: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in the fuel system and also damage plastic and rubber parts.
That damage would not be covered under your warranty.
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General Motors recommends against the use of such
gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the
emission control system may be affected. The malfunction indicator lamp may turn on.
FUELS IN FOREIGN COUNTRIES
If you plan on driving in another country outside the United States or Canada, the proper fuel might
be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text
on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty.
To check the fuel availability, ask an auto club, or contact a major oil company that does business
in the country where you will be driving.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Gasoline/Gasoline Vapors Caution
Fuel: Service Precautions Gasoline/Gasoline Vapors Caution
Gasoline/Gasoline Vapors Caution
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Gasoline/Gasoline Vapors Caution > Page 10198
Fuel: Service Precautions Actions to Take When Working with Fuel Caution
Actions to Take When Working with Fuel Caution
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Page 10199
Fuel: Testing and Inspection
Alcohol/Contaminants-in-Fuel Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Test Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system
is contaminated with water, inspect the fuel system components for rust or deterioration.
Ethanol concentrations of greater than 10 percent in nonblended gasoline, or greater than 85
percent with E85 blended gasoline for flexible fuel applications, can cause driveability conditions
such as hesitation, lack of power, stalling, or a no start, and may contribute to fuel system
corrosion, deterioration of fuel system components, and a restricted fuel filter.
Special Tools
J 44175 Fuel Composition Tester
System Verification
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear.
If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the
bottom of the sample, perform the Particulate Contaminants in Fuel Testing Procedure. If alcohol
contamination is suspected, perform the Alcohol in Fuel Testing procedure.
Alcohol in Fuel Testing with Special Tool
1. Test the fuel composition using J 44175 and Instruction Manual. 2. If water appears in the fuel
sample, clean the fuel system. 3. Subtract 50 from the reading on the DMM in order to obtain the
percentage of alcohol in the fuel sample. 4. If the nonblended gasoline fuel sample measures more
than 15 percent ethanol, or if the E85 blended gasoline fuel sample measures more than 91
percent ethanol, add fresh regular gasoline to the vehicles's fuel tank.
5. Test the fuel composition. 6. If additional testing indicates that the ethanol percentage is still
above 15 percent for a nonblended gasoline sample, drain and replace the vehicle's
fuel. Refer to Fuel Tank Draining. If additional testing indicates that the E85 blended gasoline
sample still measures above 91 percent, continue adding fresh, regular gasoline until the ethanol
content is 85 percent or less.
Alcohol in Fuel Testing without Special Tool
1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder
with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid
volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15
seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper
and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for
approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the
fuel, the
volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml
(0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this
indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat
more because this procedure does not extract all of the alcohol from the fuel.
Particulate Contaminants in Fuel Testing Procedure
1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the
container on a level surface for approximately 5 minutes in order to allow settling of the particulate
contamination. Particulate
contamination will show up in various shapes and colors. Sand will typically be identified by a white
or light brown crystals. Rubber will appear as black and irregular particles.
3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel
system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Page 10200
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel System Cleaning See: Service and Repair
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 10206
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 10207
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 10208
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 10217
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 10218
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 10219
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 10220
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's
Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 10226
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 10227
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 10228
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 10229
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Fuel Injector Resistance.......................................................................................................................
..................................................................11-14 ohms
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 10232
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Pressure Drop......................................................................................................................................
................................................................20 kPa (3 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions
Fuel Injector: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10235
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10236
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10237
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10238
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10239
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10240
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10241
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10242
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10243
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10244
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10245
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10246
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10247
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10248
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10249
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10250
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10251
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10252
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10253
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10254
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10255
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10256
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10257
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuel Injector: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10305
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10306
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10308
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10311
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10313
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10314
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10319
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10320
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10322
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10324
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10328
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 10354
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10355
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information > Diagrams > Diagram Information and Instructions > Page 10356
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10357
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information > Diagrams > Diagram Information and Instructions > Page 10358
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 10359
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10361
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 10362
Fuel Injector: Connector Views
Component Connector End Views
Fuel Injector 1 (LS4)
Fuel Injector 2 (LS4)
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Fuel Injector 3 (LS4)
Fuel Injector 4 (LS4)
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Fuel Injector 5 (LS4)
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Fuel Injector 6 (LS4)
Fuel Injector 7 (LS4)
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Fuel Injector 8 (LS4)
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service Precautions > Technician Safety Information
Fuel Injector: Technician Safety Information
Lower O-Ring Removal Caution
Caution: Verify that the lower (small) O-ring of each injector does not remain in the lower manifold
in order to reduce the risk of fire and personal injury.
If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat
properly in the injector socket. Improper seating could cause a fuel leak.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service Precautions > Technician Safety Information > Page 10370
Fuel Injector: Vehicle Damage Warnings
Fuel Injector Balance Test Notice
Notice: Do Not repeat any portion of this test before running the engine in order to prevent the
engine from flooding.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector Diagnosis (w/J39021 or w/Tech 2)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the appropriate fuel injector pulse for each cylinder. The ignition
voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump
relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise
amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the
system fuel pressure that can be recorded and used to compare each injector.
Diagnostic Aids
* Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that
is causing the condition.
* Operating the vehicle over a wide temperature range may help isolate the fuel injector that is
causing the condition.
* Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector
condition may only be apparent at a certain temperature, or under certain conditions.
Special Tools
* CH-48027 Digital Pressure Gage
* J 39021 Fuel Injector Coil and Balance Tester
* J 44602 Injector Test Adapter
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
^ If the injectors measure OK, perform the Fuel Injector Balance Test-Fuel Pressure Test.
^ If not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
^ If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test-Fuel Pressure
Test for further diagnosis of the fuel injectors.
^ If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total
resistance value. Divide the total resistance value by the number of fuel injectors to obtain an
average resistance value. Subtract the lowest individual fuel injector resistance value from the
average resistance value. Compute the difference between the highest individual fuel injector
resistance value and the average resistance value. Replace the fuel injector that displays the
greatest difference above or below the average.
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 10373
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
Fuel Injector Balance Test-Fuel Pressure Test
1. Install a fuel pressure gage. 2. Turn ON the ignition, with the engine OFF.
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Command the fuel pump relay ON with a scan tool.
3. Observe the fuel pressure gage with the fuel pump commanded ON. The fuel pressure should
be 345-414 kPa (50-60 psi).
^ If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
4. Monitor the fuel pressure gage for one minute. The fuel pressure should not decrease more than
34 kPa (5 psi).
^ If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
5. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with
Tech 2.
Fuel Injector Balance Test with Special Tool
1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5
amp position. 2. Connect the J 39021 to a fuel injector with a J 44602. 3. Command the fuel pump
relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure
begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing
the Push to Start Test button on the J 39021 at the
previously selected pressure.
5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
6. Clear the Min/Max results. 7. Select Normal from the Display Mode. 8. Repeat steps 2 and 4
through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation.
Fuel Injector Balance Test with Tech 2
1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last
command, as the fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions
menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the
fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected
pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027
and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
7. Clear the Min/Max results on the CH-48027. 8. Select Normal from the Display Mode on the
CH-48027. 9. Press Enter on the scan tool to bring you back to the Select Injector screen.
10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation.
Pressure Drop Calculation
1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the
pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the
individual pressure drop values except for the injector suspected of being faulty. This is the total
pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added
together. This is the average pressure drop. The difference between
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 10374
any individual pressure drop and the average pressure drop should not be more than 20 kPa (3
psi).
^ If the difference between any individual pressure drop and the average pressure drop is more
than 20 kPa (3 psi), replace the fuel injector.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel Injector Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 10375
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (With CH 47976)
Fuel Injector Diagnosis (w/CH47976)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the appropriate fuel injector pulse for each cylinder. The ignition
voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
The CH-47976 is used to test the fuel pump, the fuel system leak down, and the fuel injectors.
Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the
steps required to perform each of the available tests. The tester will perform all of the tests
automatically and display results of the test. The results can also be down loaded for storage and
printing.
Special Tools
CH-47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
^ If the injectors measure OK, perform the AFIT Test Procedure.
^ If not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
^ If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure.
^ If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total
resistance value. Divide the total resistance value by the number of fuel injectors to obtain an
average resistance value. Subtract the lowest individual fuel injector resistance value from the
average resistance value. Compute the difference between the highest individual fuel injector
resistance value and the average resistance value. Replace the fuel injector that displays the
greatest difference above or below the average.
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
AFIT Test Procedure
1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. 4. Turn ON the AFIT and
select the vehicle. 5. Turn ON the ignition and perform the Injector Test.
^ If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis.
See: Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 10376
6. View the test results.
^ If any injector exceeds the recommended tolerance, replace the injector(s).
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel Injector Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures
Fuel Injector: Procedures
Fuel Injector Cleaning
Tools Required
* J 37287 Fuel Line Shut-Off Adapters
* J 35800-A Fuel Injector Cleaner
* J 42873-1 3/8 Fuel Line Shut-Off Valve
* J 42873-2 5/16 Return Pipe Shut-Off Valve
* J 42964-1 3/8 Fuel Pipe Shut-Off Valve
* J 42964-2 5/16 Fuel Pipe Shut-Off Valve
Notice:
* GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended.
DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN
DAMAGE FUEL SYSTEM COMPONENTS.
* Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the
vehicle fuel tank, as it may damage the fuel pump and other system components.
* Do not exceed the recommended cleaning solution concentration. Higher concentrations may
damage fuel system components. Testing has demonstrated that exceeding the recommended
cleaning solution concentration does not improve the effectiveness of this procedure.
Important: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have the injectors replaced.
1. Obtain J 35800-A (2).
Important: Make sure the valve at the bottom of the canister (3) is closed.
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner twin reservoir
container into the J 35800-A, injector cleaning tank, then add 420 ml (14 oz) of regular unleaded
gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of
GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded
gasoline.
3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner twin reservoir container into
the J 35800-A, injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you
are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper
Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This
procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml
total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of
gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional
instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel
pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel
feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped,
coming off the fuel rail with J
37287, or J 42964-1, and J 42964-2 or J 42873-1, and J 42873-2 as appropriate for the fuel
system.
7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 10379
11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above
procedure should be done.
When the injector restriction returns to zero, proceed to step 12.
12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil
pressure switch connector, if equipped. 14. Remove the J 37287, or J 42964-1 and J 42964-2, or J
42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the
vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail
and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011
(Canadian P/N 88861012) into a nearly empty tank and advise the
customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel
System Treatment Plus to the fuel tank at every oil
change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to
repeat the injector cleaning procedure.
18. Road test the vehicle to verify that the customer concern has been corrected.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 10380
Fuel Injector: Removal and Replacement
Fuel Injector Replacement
Removal Procedure
1. Remove the fuel rail. 2. Remove the fuel injector retaining clip (521), as required. 3. Remove the
fuel injector (533), as required 4. Remove and discard the fuel injector O-ring seals (532, 534), as
required.
Installation Procedure
Important: Do not use the fuel injector O-ring seals again. Install NEW fuel injector O-ring seals
during assembly.
1. Lubricate the NEW O-ring seals with clean engine oil. 2. Install the NEW fuel injector O-ring
seals (532, 534) onto the injector, as required. 3. Install the fuel injector (533), as required 4. Install
the fuel injector retaining clip (521), as required. 5. Install the fuel rail.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service
Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service
Metal Collar Quick Connect Fitting Service
Special Tools
J 37088-A Fuel Line Disconnect Tool Set
Removal Procedure
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Remove the retainer from the fuel feed quick-connect
fitting.
Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause eye
injury.
3. Using compressed air, blow any dirt or debris from around the fitting.
4. Using the correct tool from the J 37088-A, insert the tool into the female connector, then push
inward in order to release the quick connect locking
tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 10385
5. Pull the fuel line connection apart.
Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial
motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean
shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs.
Clean or replace the components and assemblies as required.
6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting
for dirt and burrs. Clean or replace the components as required.
Installation Procedure
Caution: Refer to Fuel Pipe Fitting Caution.
1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 10386
4. Install the retainer to the fuel feed quick-connect fitting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 10387
Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Removal Procedure
Important: There are several types of plastic fuel and evaporative emission (EVAP) quick connect
fittings used on this vehicle. The following instructions apply to all types of plastic quick connect
fittings except where indicated.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027).
Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause eye
injury.
2. Use compressed air, blow and dirt or debris from around the quick-connect fitting.
3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect
fitting. (This step applies to Bartholomew style
fittings ONLY).
4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick
connect fitting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 10388
5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick
connect fitting.
6. Pull the quick connect fitting connection apart.
Installation Procedure
Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings,
always apply a few drops of clean engine oil to the male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap
into place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 10389
3. Once installed, pull on both sides of the quick connect fittings in order to ensure that the
connection is secure.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)..................................................................................................
..............................................345-414 kPa (50-60 psi)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information > Page 10396
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Special Tools
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Refer to Relieving Fuel Pressure Caution.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the
shop towel from around the fuel rail service port, and place in an approved gasoline container. 4.
Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to
the manufactures directions.
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10399
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Tighten the fuel fill cap.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10400
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the fuel pump relay when the ignition switch is turned ON. The control
module will disable the fuel pump relay within 2 seconds unless the control module detects ignition
reference pulses. The control module continues to enable the fuel pump relay as long as ignition
reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if
ignition reference pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
*
Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa
(50-60 psi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 10401
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel
Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel
rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a
scan tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF
with a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the fuel pump module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Assembly Replacement
* Fuel Injector Replacement
* Fuel Tank Fuel Pump Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions
Fuel Pump Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10407
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10408
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10409
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10410
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10411
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10412
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10413
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10415
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10416
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10417
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10418
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10419
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10420
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10421
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10422
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10423
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10424
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10425
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10426
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10427
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10428
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10429
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10430
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10431
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10432
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10433
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10434
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10435
Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10436
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10437
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10449
1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10450
3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10451
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10452
7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10453
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10454
4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10455
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10456
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10457
6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10458
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10459
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10460
1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10461
Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10462
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10463
* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10464
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10465
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10466
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10467
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10470
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10471
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10472
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10473
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10474
7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10475
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10476
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10477
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10478
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10479
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10480
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10481
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10482
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10483
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10484
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10485
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10486
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10487
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10488
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10489
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10490
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10491
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10492
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10493
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10494
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10495
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10496
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10497
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10498
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10499
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10500
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10501
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10502
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10503
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10504
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10505
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10506
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10507
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10508
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10509
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10510
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10511
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10512
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10514
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10515
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10516
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10517
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10518
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10520
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10521
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10522
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10523
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10524
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10525
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10526
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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> Component Information > Diagrams > Diagram Information and Instructions > Page 10527
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10528
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10529
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10530
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10531
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10532
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 10533
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Customer Safety Information
Fuel Rail: Customer Safety Information
Fuel Rail Stop Bracket Installation Caution
Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket
serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail
stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed
possibly causing a fire and personal injury from burns.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Customer Safety Information > Page 10538
Fuel Rail: Vehicle Damage Warnings
Fuel Rail Notice
Notice:
* Use care when servicing the fuel system components, especially the fuel injector electrical
connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the
fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail
components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail
assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10539
Fuel Rail: Service and Repair
Fuel Injection Fuel Rail Assembly Replacement
Removal Procedure
Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas
prior to disconnecting the lines in order the avoid possible system contamination.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Remove the air cleaner outlet duct. 3. Disconnect the following
electrical connectors:
* EVAP purge solenoid (1)
* Manifold absolute pressure (MAP) sensor (2)
* Electronic throttle control (ETC) (3)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)
4. Disconnect the generator electrical connector (2).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10540
5. Remove the connector position assurance (CPA) retainer (3). 6. Disconnect the main ignition coil
harness electrical connector (4).
Important: Mark the injector connectors to their corresponding injectors to ensure correct
reassembly.
7. Disconnect the fuel injector electrical connectors (1, 2).
8. Remove the CPA retainer (3). 9. Disconnect the main ignition coil harness electrical connector
(1).
Important: Mark the injector connectors to their corresponding injectors to ensure correct
reassembly.
10. Disconnect the fuel injector electrical connectors (2, 4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10541
11. Remove the engine wiring harness retainers from the tabs on the fuel rail. Reposition the
harness out of the way.
12. Disconnect the fuel feed (1) and EVAP (2) lines.
13. Note the location of the fuel rail ground strap (557).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10542
14. Remove the intake manifold bolt (512) and ground strap (557). 15. Remove the fuel rail bolts
(511). 16. Remove the fuel rail (510) with injectors. Lift evenly on both sides of the fuel rail until all
injectors have been removed from their bores.
Important: Do not separate the fuel injectors from the fuel rail unless component service is
required.
17. If replacing the fuel rail, remove the fuel injectors.
Installation Procedure
Important: Do not reuse the fuel injector O-ring seals. Install NEW O-ring seals during assembly.
1. Note the installed location of the fuel rail ground strap (557).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10543
2. If replacing the fuel rail, install the fuel injectors. 3. If necessary, Lubricate the NEW O-ring seals
with clean engine oil. 4. If necessary, install NEW O-ring seals to the fuel injectors. 5. Install the
fuel rail (510) with injectors. Push firmly on both sides of the rail until all the injectors have been
seated into their bores. 6. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian
P/N 10953489) or equivalent to the threads of the fuel rail bolts.
Notice: Refer to Fastener Notice.
7. Install the fuel rail bolts (511).
Tighten the bolts to 10 N.m (89 lb in).
8. Install the ground strap (557) and intake manifold bolt (512).
Tighten the bolt to 10 N.m (89 lb in).
9. Connect the fuel feed (1) and EVAP (2) lines.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10544
10. Position the harness to the engine. Install the engine wiring harness retainers to the tabs on the
fuel rail.
Important: Install the marked injector connectors to their corresponding injectors.
11. Connect the fuel injector electrical connectors (2, 4). 12. Connect the main ignition coil harness
electrical connector (1). 13. Install the CPA retainer (3).
Important: Install the marked injector connectors to their corresponding injectors.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Page 10545
14. Connect the fuel injector electrical connectors (1, 2). 15. Connect the main ignition coil harness
electrical connector (4). 16. Install the CPA retainer (3).
17. Connect the generator electrical connector (2).
18. Connect the following electrical connectors:
* EVAP purge solenoid (1)
* MAP sensor (2)
* ETC (3)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)
19. Install the air cleaner outlet duct. 20. Connect the negative battery cable. 21. Use the following
steps to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10
seconds. 3. Turn the ignition ON with the engine OFF. 4. Inspect for leaks.
22. Install the engine sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair
Fuel Return Line: Service and Repair
Fuel Hose/Pipes Assembly Replacement
Removal Procedure
Important: Clean the fuel connection and surrounding areas prior to disconnecting the lines in order
to avoid possible system contamination.
1. Remove the engine sight shield. 2. Remove the air cleaner outlet duct. 3. Remove the brake
master cylinder and reposition. 4. Relieve the fuel system. Refer to Fuel Pressure Relief (With CH
48027) Fuel Pressure Relief (Without CH 48027). 5. Disconnect the fuel feed line (1) from the fuel
rail.
6. Open the fuel/brake pipe retainers (1). 7. Remove the fuel feed line from the fuel/brake pipe
retainers (1). 8. Raise and support the vehicle. Refer to Vehicle Lifting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10549
9. Remove the fuel/brake line retainer bolt.
10. Remove the fuel feed line from the retainer.
11. Remove the fuel/brake line push in retainer from the underbody. 12. Remove the fuel feed line
from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10550
13. Remove the fuel/brake line retainer bolts. 14. Remove the fuel feed line from the retainer.
15. Open the fuel/brake line retainer (1). 16. Remove the fuel feed line from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10551
17. Disconnect the fuel feed (3) and evaporative emission (EVAP) (4) lines from the fuel tank lines
(1, 2). 18. Remove the fuel feed line.
Installation Procedure
1. Position the fuel feed line. 2. Connect the fuel feed (3) and EVAP (4) lines to the fuel tank lines
(1, 2).
3. Install the fuel feed line to the retainer. 4. Close the fuel/brake line retainer (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10552
5. Install the fuel feed line to the retainer.
Notice: Refer to Fastener Notice.
6. Install the fuel/brake line retainer bolts.
Tighten the bolts to 10 N.m (89 lb in).
7. Install the fuel feed line to the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10553
8. Install the fuel/brake line push in retainer to the underbody.
9. Install the fuel feed line to the retainer.
10. Install the fuel/brake line retainer bolt.
Tighten the bolt to 10 N.m (89 lb in).
11. Lower the vehicle.
12. Install the fuel feed line to the fuel/brake pipe retainers (1). 13. Close the fuel/brake pipe
retainers (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Page 10554
14. Connect the fuel feed line (1) to the fuel rail. 15. Position and install the brake master cylinder.
Refer to Master Cylinder Replacement. 16. Install the air cleaner outlet duct. 17. Install the fuel fill
cap. 18. Connect the negative battery cable. 19. Perform the following steps to inspect for leaks:
1. Turn ON the ignition for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the
ignition. 4. Inspect the system for leaks.
20. Install the engine sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair
Fuel Supply Line: Service and Repair
Fuel Hose/Pipes Assembly Replacement
Removal Procedure
Important: Clean the fuel connection and surrounding areas prior to disconnecting the lines in order
to avoid possible system contamination.
1. Remove the engine sight shield. 2. Remove the air cleaner outlet duct. 3. Remove the brake
master cylinder and reposition. 4. Relieve the fuel system. Refer to Fuel Pressure Relief (With CH
48027) Fuel Pressure Relief (Without CH 48027). 5. Disconnect the fuel feed line (1) from the fuel
rail.
6. Open the fuel/brake pipe retainers (1). 7. Remove the fuel feed line from the fuel/brake pipe
retainers (1). 8. Raise and support the vehicle. Refer to Vehicle Lifting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10558
9. Remove the fuel/brake line retainer bolt.
10. Remove the fuel feed line from the retainer.
11. Remove the fuel/brake line push in retainer from the underbody. 12. Remove the fuel feed line
from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10559
13. Remove the fuel/brake line retainer bolts. 14. Remove the fuel feed line from the retainer.
15. Open the fuel/brake line retainer (1). 16. Remove the fuel feed line from the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10560
17. Disconnect the fuel feed (3) and evaporative emission (EVAP) (4) lines from the fuel tank lines
(1, 2). 18. Remove the fuel feed line.
Installation Procedure
1. Position the fuel feed line. 2. Connect the fuel feed (3) and EVAP (4) lines to the fuel tank lines
(1, 2).
3. Install the fuel feed line to the retainer. 4. Close the fuel/brake line retainer (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10561
5. Install the fuel feed line to the retainer.
Notice: Refer to Fastener Notice.
6. Install the fuel/brake line retainer bolts.
Tighten the bolts to 10 N.m (89 lb in).
7. Install the fuel feed line to the retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10562
8. Install the fuel/brake line push in retainer to the underbody.
9. Install the fuel feed line to the retainer.
10. Install the fuel/brake line retainer bolt.
Tighten the bolt to 10 N.m (89 lb in).
11. Lower the vehicle.
12. Install the fuel feed line to the fuel/brake pipe retainers (1). 13. Close the fuel/brake pipe
retainers (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 10563
14. Connect the fuel feed line (1) to the fuel rail. 15. Position and install the brake master cylinder.
Refer to Master Cylinder Replacement. 16. Install the air cleaner outlet duct. 17. Install the fuel fill
cap. 18. Connect the negative battery cable. 19. Perform the following steps to inspect for leaks:
1. Turn ON the ignition for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the
ignition. 4. Inspect the system for leaks.
20. Install the engine sight shield.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement
Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement
Fuel Tank Filler Pipe Replacement
Removal Procedure
Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas
prior to disconnecting the lines in order to avoid possible system contamination.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Remove the fuel fill pipe screws from the fuel filler pocket.
3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the fill pipe bracket bolt (4)
from the underbody rail. 5. Remove the EVAP line (2) from the bracket (3).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10569
6. Loosen the fuel fill pipe clamp (1) at the fuel tank. 7. Remove the fuel fill pipe hose (2) from the
fuel tank (3). 8. Disconnect the vent pipe quick connect fitting from the fuel tank vent pipe quick
connect fitting.
9. Remove the fuel tank fill pipe.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10570
1. Install the fuel tank fill pipe.
2. Install the fuel tank fill pipe hose (2) onto the fuel tank (3) 3. Connect the vent pipe quick connect
fitting to the fuel tank vent pipe quick connect fitting.
Notice: Refer to Fastener Notice.
4. Tighten the fuel fill pipe clamp (1) at the fuel tank.
Tighten the clamp to 2.5 N.m (22 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10571
5. Install the EVAP line (2) to the bracket (3). 6. Install the fill pipe bracket bolt (4) to the underbody
rail.
Tighten the bolt to 13 N.m (115 lb in).
7. Lower the vehicle.
8. Install the fuel fill pipe screws to the fuel filler pocket.
Tighten the screws to 2.5 N.m (22 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10572
Fuel Filler Hose: Service and Repair Filler Tube Replacement
Filler Tube Replacement
Removal Procedure
Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas
prior to disconnecting the lines in order to avoid possible system contamination.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure
Relief (Without CH 48027). 2. Remove the fuel fill pipe screws from the fuel filler pocket.
3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the fill pipe bracket bolt (4)
from the underbody rail. 5. Remove the EVAP line (2) from the bracket (3).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10573
6. Loosen the fuel fill pipe clamp (1) at the fuel tank. 7. Remove the fuel fill pipe hose (2) from the
fuel tank (3). 8. Disconnect the vent pipe quick connect fitting from the fuel tank vent pipe quick
connect fitting.
9. Remove the fuel tank fill pipe.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10574
1. Install the fuel tank fill pipe.
2. Install the fuel tank fill pipe hose (2) onto the fuel tank (3) 3. Connect the vent pipe quick connect
fitting to the fuel tank vent pipe quick connect fitting.
Notice: Refer to Fastener Notice.
4. Tighten the fuel fill pipe clamp (1) at the fuel tank.
Tighten the clamp to 2.5 N.m (22 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement > Page 10575
5. Install the EVAP line (2) to the bracket (3). 6. Install the fill pipe bracket bolt (4) to the underbody
rail.
Tighten the bolt to 13 N.m (115 lb in).
7. Lower the vehicle.
8. Install the fuel fill pipe screws to the fuel filler pocket.
Tighten the screws to 2.5 N.m (22 lb in).
9. Install the intake manifold cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Diagrams
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Fuel Tank Unit: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
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Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
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^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
Fuel Pump Relay: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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> Page 10596
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10598
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10599
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
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> Page 10602
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10603
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10604
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10605
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10606
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10607
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10608
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10609
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10611
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10612
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10613
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10614
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10615
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10616
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10617
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10618
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10619
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> Page 10620
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> Page 10621
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10622
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10623
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10624
Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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> Page 10626
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10628
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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> Page 10660
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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> Page 10674
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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> Page 10677
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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> Page 10679
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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> Page 10680
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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> Page 10681
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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> Page 10684
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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> Page 10685
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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> Page 10689
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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> Page 10690
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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> Page 10691
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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> Page 10696
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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> Page 10697
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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> Page 10699
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10707
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10708
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10709
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10710
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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> Page 10711
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10712
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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> Page 10713
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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> Page 10714
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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> Page 10715
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10716
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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> Page 10717
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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> Page 10718
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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> Page 10719
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10720
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10721
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 10722
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
IGN MAIN RELAY
The Ign Main PCB relay is located in the Underhood Fuse Block (1). The Underhood Fuse Block
(1) is located on the right side of the engine compartment, mounted to the strut tower.
IMPORTANT: This relay is a Printed Circuit Board (PCB) relay, and is only repaired by replacing
the Underhood Fuse Block.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 10726
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test
Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 10727
^ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood
fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
^ If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
^ If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
^ If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
^ If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
^ If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
^ If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is
open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal,
replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
^ If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup
* Engine Control Module Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
^ If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 10732
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 10733
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the left instrument panel (I/P) sound insulator. 2. Disconnect the accelerator pedal
position (APP) sensor electrical connector (1).
3. Remove the APP sensor assembly bolts. 4. Remove the APP sensor assembly from the vehicle.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 10734
1. Position the APP sensor assembly to the vehicle.
Notice: Refer to Fastener Notice.
2. Install the APP sensor assembly bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Connect APP sensor electrical connector (1) 4. Install the left I/P sound insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Powertrain Component Views
Air Flow Meter/Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Top Side of Engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Powertrain Component Views >
Page 10739
Left Top Side Of Engine
1 - Throttle Body 2 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 3 - Mass
Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor Connector
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Powertrain Component Views >
Page 10740
Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10743
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10744
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10745
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10746
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10747
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10748
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10749
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10750
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10751
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10752
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10753
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10754
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10755
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10756
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10757
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10758
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10759
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10760
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10761
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10762
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10763
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10764
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10765
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10766
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10767
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10768
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10769
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10770
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10771
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10772
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10773
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10774
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Instructions > Page 10847
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Instructions > Page 10848
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10850
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10851
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10852
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 10854
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10855
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10856
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 10859
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Instructions > Page 10860
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10861
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10862
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10863
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 10864
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10865
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10866
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10867
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10868
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10869
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10870
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 10871
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
1. Remove the air intake duct. 2. Disconnect the mass air flow (MAF)/intake air temperature (IAT)
sensor electrical connector (2).
3. Remove the MAF/IAT sensor bolts. 4. Remove the MAF/IAT sensor from the air cleaner housing.
5. Remove the MAF/IAT sensor seal, if necessary.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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1. Install the MAF/IAT sensor seal, if necessary. 2. Install the MAF/IAT sensor to the air cleaner
housing.
Notice: Refer to Fastener Notice.
3. Install the MAF/IAT sensor bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the MAF/IAT sensor electrical connector (2). 5. Install the air intake duct.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10877
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10878
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10879
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10880
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10881
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10882
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10883
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10884
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10885
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10886
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10887
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10888
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10889
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10890
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10891
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10892
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10893
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10894
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10895
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10896
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10897
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10898
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10899
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10900
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10901
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10902
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10903
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10904
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10905
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Instructions > Page 10906
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10907
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Instructions > Page 10908
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Instructions > Page 10950
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Instructions > Page 10954
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Instructions > Page 10958
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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Instructions > Page 10961
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Instructions > Page 10965
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Instructions > Page 10966
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Instructions > Page 10982
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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Instructions > Page 10983
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10984
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Instructions > Page 10985
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10986
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Instructions > Page 10989
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10990
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10992
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Instructions > Page 10994
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10995
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10996
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10997
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 10998
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 10999
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 11000
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Instructions > Page 11001
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 11002
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 11003
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Diagrams
Throttle Body: Diagrams
Component Connector End Views - Continued
Throttle Body (LS4)
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Throttle Body: Procedures
Throttle Learn
Throttle Learn
Description
The engine control module (ECM) learns the airflow through the throttle body to ensure the correct
idle. The learned airflow values are stored within the ECM. These values are learned to adjust for
production variation and will continuously learn during the life of the vehicle to compensate for
reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to
cleaning or replacing, the values must be relearned.
A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take
several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability
to reset all learned values back to zero. A new ECM will also have values set to zero.
The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.
Conditions for Running the Throttle Learn Procedure
With Scan Tool - Reset Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* Ignition ON, engine OFF.
* The vehicle speed sensor (VSS) is 0 km/h (0 mph).
Without Scan Tool - Learn Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* The engine speed is between 450-4,000 RPM.
* The manifold absolute pressure (MAP) is greater than 5 kPa.
* The mass air flow (MAF) is greater than 2 g/s.
* The ignition 1 voltage is greater than 10 volts.
Throttle Learn
With Scan Tool - Reset Procedure
1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2.
Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow
Compensation value should equal 0 percent and the
engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.
Without Scan Tool - Learn Procedure
Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code
(DTC) List - Vehicle. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual
RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3
minute run time the engine should be idling normal.
Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle
speed codes are set, clear codes so the ECM can continue to learn.
^ If the engine idle speed has not been learned the vehicle will need to be driven at speeds above
70 km/h (44 mph) with several decelerations and extended idles.
7. After the drive cycle, the engine should be idling normally.
^ If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat
step 6.
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8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that
referred you here.
Throttle Body Cleaning
Throttle Body Cleaning
1. Remove the air cleaner intake duct.
Caution: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement
of the throttle blade could cause personal injury.
Notice: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle
valve plate.
2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the
throttle plate in order to inspect all surfaces.
Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage
fuel system components.
3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine
Cleaner, P/N 1052626 or AC-Delco Carburetor
Tune-Up Conditioner, P/N X66-P, or an equivalent product.
4. Install the air cleaner intake duct.
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Throttle Body: Removal and Replacement
Throttle Body Assembly Replacement
Removal Procedure
Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to
prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the
electronic throttle control components. Do not immerse the electronic throttle control components in
cleaning solvents of any type.
Important:
* DO NOT for any reason, insert a screwdriver or other small hand tool into the throttle body to hold
open the throttle plate as a wedge, as the inside of the throttle body could be damaged.
* An 8 digit part identification number is stamped on the throttle body casting. Refer to this number
if servicing, or part replacement is required.
1. Remove the engine sight shield. 2. Remove the air cleaner outlet duct. 3. Disconnect the throttle
actuator control motor electrical connector (3).
4. Disconnect the evaporative emission (EVAP) canister purge tube from the throttle body.
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5. Remove the throttle body bolts (538). 6. Remove the throttle body (508). 7. Remove and discard
the throttle body gasket (509).
Installation Procedure
Important: DO NOT reuse the throttle body gasket. Install a NEW gasket during assembly.
1. Install a NEW throttle body gasket (509). Align the locating tab of the gasket with the notch in the
manifold. 2. Position the throttle body (508) to the intake manifold.
Notice: Refer to Fastener Notice.
3. Install the throttle body bolts (538).
Tighten the bolts to 10 N.m (89 lb in).
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4. Connect the EVAP canister purge tube to the throttle body.
Important: Verify that the throttle actuator motor harness connector and the connector seal are
properly installed and not damaged.
5. Connect the throttle actuator control motor electrical connector (3). 6. Install the air cleaner outlet
duct. 7. Install the engine sight shield. 8. Connect a scan tool in order to test for proper throttle
opening and throttle closing ranges. 9. Operate the accelerator pedal and monitor the throttle
angles. The accelerator pedal should operate freely, without binding, between closed
throttle, and wide open throttle (WOT).
10. Verify that the vehicle meets the following conditions:
* The vehicle is not in a reduced engine power mode.
* The ignition is ON.
* The engine is OFF.
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Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 11046
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 11087
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11088
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11089
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11090
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11091
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11092
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11093
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11094
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11095
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11096
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11097
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11098
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11099
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11100
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11101
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11102
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11103
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11104
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11105
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 11106
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11107
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11108
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11109
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 11110
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11111
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11112
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11113
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11115
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11116
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11117
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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Component Information > Diagrams > Diagram Information and Instructions > Page 11118
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11119
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11120
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11130
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11135
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11136
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
...........................................................1-8-7-2-6-5-4-3
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11187
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11188
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Information > Diagrams > Diagram Information and Instructions > Page 11189
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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Information > Diagrams > Diagram Information and Instructions > Page 11190
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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Information > Diagrams > Diagram Information and Instructions > Page 11197
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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Information > Diagrams > Diagram Information and Instructions > Page 11202
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Information > Diagrams > Diagram Information and Instructions > Page 11204
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11251
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 11258
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11260
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11265
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11266
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information > Diagrams > Diagram Information and Instructions > Page 11267
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11268
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11269
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Information > Diagrams > Diagram Information and Instructions > Page 11270
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information > Diagrams > Diagram Information and Instructions > Page 11271
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 11272
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11273
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information > Diagrams > Diagram Information and Instructions > Page 11274
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11275
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11276
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11277
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 11393
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11403
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11404
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11405
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11406
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11407
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11408
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11409
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11410
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11411
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11412
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11413
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 11415
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 11418
1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 11419
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
...........................................................397-1,337 ohms
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 11423
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
following conditions:
1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of
cracks or splits in the wires. 3. Inspect each boot for the following conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 11424
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the spark plug wire from the spark plug.
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the spark plug.
2. Remove the spark plug wire from the ignition coil (724).
1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire
from the ignition coil.
Installation Procedure
1. Install the spark plug wire to the ignition coil (724). 2. Install the spark plug wire to the spark plug.
3. Inspect the spark plug wire for proper installation:
1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams
Ignition Coil: Diagrams
Component Connector End Views - Continued
Ignition Coil 1 (LS4)
Ignition Coil 2 (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11428
Ignition Coil 3 (LS4)
Ignition Coil 4 (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11429
Ignition Coil 5 (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11430
Ignition Coil 6 (LS4)
Ignition Coil 7 (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11431
Ignition Coil 8 (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11432
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Diagrams > Page 11433
Ignition Coil: Service and Repair
Ignition Coil Replacement
Removal Procedure
Important: The following procedure shows the left side service procedure, the right side service
procedure is similar.
1. Remove the engine sight shield. 2. Remove the connector position assurance (CPA) retainer (3).
3. Disconnect the ignition coil main electrical connector (4).
4. Remove the spark plug wire(s) (724) from the ignition coil(s), as necessary.
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5. Remove the ignition coil bolts (723), as necessary. 6. Remove the ignition coil(s) (722), as
necessary.
Installation Procedure
1. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of
the ignition coil bolts. 2. Install the ignition coil(s) (722), as necessary.
Notice: Refer to Fastener Notice.
3. Install the ignition coil bolts (723), as necessary.
Tighten the bolts to 8 N.m (71 lb in).
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4. Install the spark plug wire(s) (724) to the ignition coil(s), as necessary.
5. Connect the left ignition coil main electrical connector (4). 6. Install the CPA retainer (3). 7. Install
the engine sight shield.
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Locations
Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 11531
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Diagrams > Diagram Information and Instructions > Page 11536
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
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5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
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2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
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6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
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Camshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LS4)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt (705). 3. Remove the CMP sensor (703). 4. Inspect the CMP
sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused. 5.
Remove the CMP sensor O-ring seal (704), if necessary.
Installation Procedure
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1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal (704) onto the CMP
sensor, if necessary. 3. Install the CMP sensor (703).
Notice: Refer to Fastener Notice.
4. Remove the CMP sensor bolt (705).
Tighten the bolt to 12 N.m (106 lb in).
5. Connect the CMP sensor electrical connector.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear of Engine (LS4)
Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Crankshaft Position Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 11837
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 11839
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 11841
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 11844
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Caution: Refer to Vehicle Lifting Caution.
1. Remove the right exhaust manifold. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector (1).
Important: Clean the area around the CKP before removal in order to avoid debris from entering
the engine.
3. Remove the CKP sensor bolt. 4. Remove the CKP sensor.
Installation Procedure
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Page 11847
1. Install the CKP sensor.
Notice: Refer to Fastener Notice.
2. Install the CKP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector (1). 4. Install the right exhaust manifold. 5. Perform
the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
See:
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Page 11848
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Descriptions
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 11853
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
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7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
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are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
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Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
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cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
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22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
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Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
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7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
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3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
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7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
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Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front of Engine (LS4)
Front Of Engine
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Coil 1 3 - Ignition Coil 3 4 - Ignition Coil
5 5 - Ignition Coil 7 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Engine
Coolant Heater 9 - Knock Sensor (KS) 1 10 - Engine Oil Level Switch 11 - Camshaft Position
(CMP) Sensor
Rear of Engine (LS4)
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Rear Of Engine
1 - Ignition Coil 7 2 - Throttle Body 3 - Ignition Coil 8 4 - Ignition Coil 6 5 - Ignition Coil 4 6 - Ignition
Coil 2 7 - Heated Oxygen Sensor (HO2S) 1 8 - Knock Sensor (KS) 2 9 - Crankshaft Position (CKP)
Sensor 10 - Engine Oil Level Switch 11 - Valve Lifter Oil Manifold (VLOM) Assembly
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Knock Sensor: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) Bank 1
Knock Sensor (KS) Bank 2
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
2. Disconnect the left knock sensor electrical connector, if required.
3. Remove the left knock sensor bolt, if required. 4. Remove the left knock sensor, if required.
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Page 12002
5. Disconnect the right knock sensor electrical connector (2), if required.
6. Remove the right knock sensor bolt, if required. 7. Remove the right knock sensor, if required.
Installation Procedure
1. Position the right knock sensor to the engine block, if required.
Notice: Refer to Fastener Notice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Page 12003
2. Install the right knock sensor bolt, if required.
Tighten the bolt to 20 N.m (15 lb ft).
3. Connect the right knock sensor electrical connector (2), if required.
4. Position the left knock sensor to the engine block, if required. 5. Install the left knock sensor bolt,
if required.
Tighten the bolt to 20 N.m (15 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Page 12004
6. Connect the left knock sensor electrical connector, if required. 7. Fill the cooling system. Refer to
Cooling System Draining and Filling (9C1, 9C3 Static Fill) Cooling System Draining and Filling
(LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.......................................................1.02 mm - 0.040 in Spark Plug Torque..........................................
................................................................................................................................................15 N.m 11 lb ft
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 12008
Spark Plug: Application and ID
Spark Plug
Type..........................................................................................................................................GM
P/N 12571164 (AC Spark Plug P/N 41-985)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 12009
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling - colder plug
- Pre-ignition causing spark plug and/or engine damage - hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 12010
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively-wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over-torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes reduce or eliminates the gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 12011
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot
engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug
thread damage or cylinder head damage.
1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using
compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug.
If removing more than one plug, place each plug in a tray marked with the corresponding cylinder
number.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 12012
1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as
needed.
Spark plug gap: 1.016 mm (0.040 in).
3. Hand start the spark plug in the corresponding cylinder.
Notice: Refer to Fastener Notice.
4. Tighten the spark plug.
Tighten the plug to 15 N.m (11 lb ft).
5. Install the spark plug wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 12019
Pressure Regulating Solenoid: Service and Repair
Pressure Control Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the pressure control solenoid (PCS) electrical connector. 3. Remove the PCS
retaining clip (314E).
4. Remove the PCS (322).
Installation Procedure
1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical
connector. 4. Install the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot
Be Removed/No Shift From Park
Shift Interlock Solenoid: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot
Be Removed/No Shift From Park > Page 12028
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T Key Cannot Be Removed/No Shift From Park > Page 12034
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Page 12035
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: To prevent component damage, DO NOT use metal tools to remove the trim.
Important: Use only a plastic trim tool to lift the shift lever bezel or trim plate. Do not use any tool
between the shift lever bezel or trim plate and the shifter.
2. Remove the center console. Refer to Front Floor Console Replacement (Impala) . 3. Disconnect
the automatic transaxle shift lock actuator electrical connector (1). 4. Remove both ends of the
automatic transaxle shift lock actuator from the pivot points.
Installation Procedure
1. Install both ends of the automatic transaxle shift lock actuator to the pivot points. 2. Connect the
automatic transaxle shift lock actuator electrical connector (1). 3. Install the center console. Refer
to Front Floor Console Replacement (Impala) . 4. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle
Shift Solenoid: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle > Page 12041
Shift Solenoid: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
In the Center Console - Floor Shifter
In the Center Console - Floor Shifter
1 - Floor Shifter 2 - A/T Shift Lock Control Solenoid
Steering Column Components - Column Shift
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle > Page 12042
Lower Steering Column Components
1 - Automatic Transmission Shift Lock Control Solenoid 2 - Steering Column
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12045
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12046
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12047
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12048
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12049
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12050
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12051
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12052
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12053
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12054
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12055
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12056
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12057
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12058
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12059
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12060
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12061
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12062
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12063
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12064
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12065
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12066
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12067
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12068
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12069
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12070
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12071
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 12072
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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Diagram Information and Instructions > Page 12111
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Diagram Information and Instructions > Page 12161
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Diagram Information and Instructions > Page 12162
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 12163
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 12164
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Diagram Information and Instructions > Page 12165
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Diagram Information and Instructions > Page 12166
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagram Information and Instructions > Page 12167
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagram Information and Instructions > Page 12168
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagram Information and Instructions > Page 12169
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 12170
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Diagram Information and Instructions > Page 12172
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (1-2 SS) Valve
2-3 Shift Solenoid (2-3 SS) Valve
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Repair > 1-2 Shift Solenoid Valve Replacement
Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement
1-2 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining
clip (314D)
4. Remove the 1-2 shift solenoid (315A).
Installation Procedure
1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3.
Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
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Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining
clip (314C).
4. Remove the 2-3 shift solenoid (315B) and the O-ring (316).
Installation Procedure
1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining
clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover.
Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be
affected as new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations
Torque Converter Clutch Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 12192
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 12301
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information > Service and Repair > Torque Converter Clutch Solenoid Replacement
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid
Replacement
Torque Converter Clutch Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Remove the TCC
solenoid retaining clip (314) 4. Remove the TCC solenoid (315).
Installation Procedure
1. Install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the
TCC solenoid electrical connector. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 12311
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width
Modulation Solenoid Replacement
Torque Converter Clutch Pulse Width Modulation Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect and reposition the electrical connectors from the following:
* If equipped internal mode switch
* 2-3 Shift solenoid valve assembly (315B)
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
3. Remove the oil pump bolts (230, 231).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 12312
4. Remove the oil pump (200) from the valve body (300).
5. Disconnect the torque converter clutch pulse width modulation (TCC PWM) solenoid electrical
connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM
solenoid (334).
Installation Procedure
1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3.
Connect the TCC PWM solenoid electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 12313
4. Install the oil pump (200) to the valve body (300).
Notice: Refer to Fastener Notice .
5. Install the oil pump body and cover bolts (230, 230).
* Tighten the nine bolts (231) to 12 N.m (106 lb in).
* Tighten the two bolts (230) to 16 N.m (12 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 12314
6. Reposition and connect the electrical connectors to the following:
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
* 2-3 Shift solenoid valve assembly (315B)
* If equipped internal mode switch
7. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Transmission
and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Powertrain Component Views > Page 12321
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 12322
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 12323
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 12324
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 12331
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 12332
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 12333
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 12334
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 12339
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > Page 12340
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 12345
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 12346
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 12347
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > 4T65-E - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > 4T65-E - Automatic Transaxle > Page 12353
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > Page 12354
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement > Page 12357
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and
Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement > Page 12358
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and
Repair) .
8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Description and Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations
PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12363
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12364
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12365
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12366
PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026B
Date: April 07, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2010 model year and information about
retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number
09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle)
to stresses that were not tested by General Motors. It is because of these unknown stresses, and
the potential to alter reliability, durability and emissions performance, that GM has adopted a policy
that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty
coverage, to the powertrain and driveline components whenever the presence of a non-GM
(aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12367
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12368
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the
complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 12369
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 12376
Pressure Regulating Solenoid: Service and Repair
Pressure Control Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the pressure control solenoid (PCS) electrical connector. 3. Remove the PCS
retaining clip (314E).
4. Remove the PCS (322).
Installation Procedure
1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical
connector. 4. Install the case side cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer
Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer
Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park >
Page 12385
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No
Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No
Shift From Park > Page 12391
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Page
12392
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: To prevent component damage, DO NOT use metal tools to remove the trim.
Important: Use only a plastic trim tool to lift the shift lever bezel or trim plate. Do not use any tool
between the shift lever bezel or trim plate and the shifter.
2. Remove the center console. Refer to Front Floor Console Replacement (Impala) . 3. Disconnect
the automatic transaxle shift lock actuator electrical connector (1). 4. Remove both ends of the
automatic transaxle shift lock actuator from the pivot points.
Installation Procedure
1. Install both ends of the automatic transaxle shift lock actuator to the pivot points. 2. Connect the
automatic transaxle shift lock actuator electrical connector (1). 3. Install the center console. Refer
to Front Floor Console Replacement (Impala) . 4. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Shift Solenoid: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
> Page 12398
Shift Solenoid: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
In the Center Console - Floor Shifter
In the Center Console - Floor Shifter
1 - Floor Shifter 2 - A/T Shift Lock Control Solenoid
Steering Column Components - Column Shift
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
> Page 12399
Lower Steering Column Components
1 - Automatic Transmission Shift Lock Control Solenoid 2 - Steering Column
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Shift Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12402
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12527
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12528
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12529
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (1-2 SS) Valve
2-3 Shift Solenoid (2-3 SS) Valve
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid
Valve Replacement
Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement
1-2 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining
clip (314D)
4. Remove the 1-2 shift solenoid (315A).
Installation Procedure
1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3.
Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
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Valve Replacement > Page 12533
Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining
clip (314C).
4. Remove the 2-3 shift solenoid (315B) and the O-ring (316).
Installation Procedure
1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining
clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover.
Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve
Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be
affected as new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
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Torque Converter Clutch Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Information and Instructions > Page 12539
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Information and Instructions > Page 12540
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Information and Instructions > Page 12541
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Information and Instructions > Page 12542
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Information and Instructions > Page 12543
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Information and Instructions > Page 12544
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Information and Instructions > Page 12545
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Information and Instructions > Page 12546
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12547
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12548
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 12549
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12550
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12551
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12552
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12553
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12554
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12555
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12556
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12557
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12558
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12559
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12560
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12561
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12562
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12563
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12564
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Information and Instructions > Page 12565
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information and Instructions > Page 12566
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Information and Instructions > Page 12567
Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 12569
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 12658
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 12659
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12660
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12661
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12662
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12663
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12664
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 12665
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair >
Torque Converter Clutch Solenoid Replacement
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid
Replacement
Torque Converter Clutch Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Remove the TCC
solenoid retaining clip (314) 4. Remove the TCC solenoid (315).
Installation Procedure
1. Install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the
TCC solenoid electrical connector. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair >
Torque Converter Clutch Solenoid Replacement > Page 12668
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width
Modulation Solenoid Replacement
Torque Converter Clutch Pulse Width Modulation Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect and reposition the electrical connectors from the following:
* If equipped internal mode switch
* 2-3 Shift solenoid valve assembly (315B)
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
3. Remove the oil pump bolts (230, 231).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair >
Torque Converter Clutch Solenoid Replacement > Page 12669
4. Remove the oil pump (200) from the valve body (300).
5. Disconnect the torque converter clutch pulse width modulation (TCC PWM) solenoid electrical
connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM
solenoid (334).
Installation Procedure
1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3.
Connect the TCC PWM solenoid electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair >
Torque Converter Clutch Solenoid Replacement > Page 12670
4. Install the oil pump (200) to the valve body (300).
Notice: Refer to Fastener Notice .
5. Install the oil pump body and cover bolts (230, 230).
* Tighten the nine bolts (231) to 12 N.m (106 lb in).
* Tighten the two bolts (230) to 16 N.m (12 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair >
Torque Converter Clutch Solenoid Replacement > Page 12671
6. Reposition and connect the electrical connectors to the following:
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
* 2-3 Shift solenoid valve assembly (315B)
* If equipped internal mode switch
7. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 12677
Pressure Regulating Solenoid: Service and Repair
Pressure Control Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the pressure control solenoid (PCS) electrical connector. 3. Remove the PCS
retaining clip (314E).
4. Remove the PCS (322).
Installation Procedure
1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical
connector. 4. Install the case side cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for
Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for
Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park > Page 12686
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park >
Page 12692
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Page 12693
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: To prevent component damage, DO NOT use metal tools to remove the trim.
Important: Use only a plastic trim tool to lift the shift lever bezel or trim plate. Do not use any tool
between the shift lever bezel or trim plate and the shifter.
2. Remove the center console. Refer to Front Floor Console Replacement (Impala) . 3. Disconnect
the automatic transaxle shift lock actuator electrical connector (1). 4. Remove both ends of the
automatic transaxle shift lock actuator from the pivot points.
Installation Procedure
1. Install both ends of the automatic transaxle shift lock actuator to the pivot points. 2. Connect the
automatic transaxle shift lock actuator electrical connector (1). 3. Install the center console. Refer
to Front Floor Console Replacement (Impala) . 4. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Shift Solenoid: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 12699
Shift Solenoid: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
In the Center Console - Floor Shifter
In the Center Console - Floor Shifter
1 - Floor Shifter 2 - A/T Shift Lock Control Solenoid
Steering Column Components - Column Shift
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 12700
Lower Steering Column Components
1 - Automatic Transmission Shift Lock Control Solenoid 2 - Steering Column
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12703
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12704
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12705
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12706
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12707
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12708
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12709
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12710
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12711
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
12712
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (1-2 SS) Valve
2-3 Shift Solenoid (2-3 SS) Valve
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Replacement
Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement
1-2 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining
clip (314D)
4. Remove the 1-2 shift solenoid (315A).
Installation Procedure
1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3.
Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
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Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining
clip (314C).
4. Remove the 2-3 shift solenoid (315B) and the O-ring (316).
Installation Procedure
1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining
clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover.
Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control
Valve Body Cover
Replacement) .
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be
affected as new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Instructions > Page 12841
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12842
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Instructions > Page 12843
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 12844
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 12845
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12846
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12847
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
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Instructions > Page 12848
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
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Instructions > Page 12849
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12850
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12851
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12852
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12853
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 12854
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 12855
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Instructions > Page 12856
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Instructions > Page 12857
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Instructions > Page 12858
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Instructions > Page 12859
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Instructions > Page 12860
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Instructions > Page 12861
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Instructions > Page 12862
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Instructions > Page 12863
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Instructions > Page 12864
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Instructions > Page 12865
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Instructions > Page 12866
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 12928
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Instructions > Page 12953
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Instructions > Page 12954
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Instructions > Page 12955
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 12956
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Instructions > Page 12957
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 12958
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 12959
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 12960
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 12961
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 12962
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Instructions > Page 12963
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Instructions > Page 12964
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 12965
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Instructions > Page 12966
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Converter Clutch Solenoid Replacement
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid
Replacement
Torque Converter Clutch Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Remove the TCC
solenoid retaining clip (314) 4. Remove the TCC solenoid (315).
Installation Procedure
1. Install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the
TCC solenoid electrical connector. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque
Converter Clutch Solenoid Replacement > Page 12969
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width
Modulation Solenoid Replacement
Torque Converter Clutch Pulse Width Modulation Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect and reposition the electrical connectors from the following:
* If equipped internal mode switch
* 2-3 Shift solenoid valve assembly (315B)
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
3. Remove the oil pump bolts (230, 231).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque
Converter Clutch Solenoid Replacement > Page 12970
4. Remove the oil pump (200) from the valve body (300).
5. Disconnect the torque converter clutch pulse width modulation (TCC PWM) solenoid electrical
connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM
solenoid (334).
Installation Procedure
1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3.
Connect the TCC PWM solenoid electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque
Converter Clutch Solenoid Replacement > Page 12971
4. Install the oil pump (200) to the valve body (300).
Notice: Refer to Fastener Notice .
5. Install the oil pump body and cover bolts (230, 230).
* Tighten the nine bolts (231) to 12 N.m (106 lb in).
* Tighten the two bolts (230) to 16 N.m (12 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque
Converter Clutch Solenoid Replacement > Page 12972
6. Reposition and connect the electrical connectors to the following:
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
* 2-3 Shift solenoid valve assembly (315B)
* If equipped internal mode switch
7. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair
Accumulator: Service and Repair
Accumulator and 2-1 Manual Servo Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the filter.
Refer to Automatic Transmission Fluid Filter and Seal Replacement (See: Fluid Filter - A/T/Service
and Repair) .
3. Remove the accumulator bolts (131). 4. Remove the manual 2-1 band servo cover bolts (103).
5. Remove the accumulator assembly.
6. Remove the manual 2-1 band servo (106-116).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > Page 12976
1. Install the manual 2-1 band servo (106-116).
2. Install the accumulator assembly.
Notice: Refer to Fastener Notice .
3. Install the manual 2-1 band servo cover bolts (103).
Tighten the bolts to 25 N.m (18 lb ft).
4. Install the accumulator cover bolts (131).
Tighten the bolts to 12 N.m (106 lb in).
5. Install the filter. Refer to Automatic Transmission Fluid Filter and Seal Replacement (See: Fluid
Filter - A/T/Service and Repair) . 6. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
7. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Reverse Servo Replacement
Band Apply Servo: Service and Repair Reverse Servo Replacement
Reverse Servo Replacement
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
2. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (RPO LS4)
Exhaust Crossover Pipe Replacement (RPOs
LZE/LZ4/LZ8) .
3. Depress the reverse servo cover (40). 4. Remove the snap ring (39).
5. Pull the O-ring seal (41) out through the slot in the case. 6. Use side cutting pliers in order to cut
the servo cover O-ring seal (41). 7. Depress the reverse servo cover (40), grasp one end of the cut
seal (41) and pull the seal (41) out of the servo cover (40).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Reverse Servo Replacement > Page 12981
8. Remove the reverse servo cover (40). 9. Remove the servo assembly (42-48).
10. Remove the servo spring (49).
Installation Procedure
Important: Follow this procedure exactly or the transaxle will have no reverse gear due to the servo
pin missing the band.
1. Jack up the driver side of the car until the driver side is higher than the differential side. This
ensures that the reverse band is in the proper location
and not cocked to the channel plate side of the case.
2. Install the servo spring (49). 3. Install the servo assembly (42-48). 4. Install the reverse servo
cover (40) with the new O-ring seal (41).
5. Compress the servo cover (40) and install the snap ring (39). 6. Install the exhaust crossover
pipe. Refer to Exhaust Crossover Pipe Replacement (RPO LS4) Exhaust Crossover Pipe
Replacement (RPOs
LZE/LZ4/LZ8) .
7. Install the air cleaner outlet duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Reverse Servo Replacement > Page 12982
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Reverse Servo Replacement > Page 12983
Band Apply Servo: Service and Repair Forward Servo Replacement
Forward Servo Replacement
Removal Procedure
1. Install the engine support fixture. Refer to the following:
* Engine Support Fixture for the 3.5L engine
* Engine Support Fixture for the 3.9L engine
* Engine Support Fixture for the 5.3L engine
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove and support
the power steering gear. Refer to Steering Gear Replacement (See: Steering and
Suspension/Steering/Steering Gear/Service
and Repair) .
4. Remove the transaxle mount lower nuts. Refer to Transmission Mount Replacement - Left Side
(See: Transmission Mount/Service and
Repair/Transmission Mount Replacement - Left Side) .
5. Remove the engine mount lower nuts. Refer to the following:
* Engine Mount Replacement for the 3.5L engine
* Engine Mount Replacement for the 3.9L engine
* Engine Mount Replacement - Right Side for the 5.3L engine
6. Remove the power steering lines from the right side of the frame. 7. Support the rear of the
frame with a jackstand. 8. Loosen the front frame bolts and remove the rear frame bolts. Refer to
Frame Replacement . 9. Adjust the jackstand to lower the rear of the frame.
10. Position a drain pan under the forward servo cover.
11. Remove the servo cover bolts. 12. Remove the forward servo cover. 13. Remove the forward
servo cover O-ring. 14. Remove the servo piston assembly. 15. Remove the servo spring.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T
> Component Information > Service and Repair > Reverse Servo Replacement > Page 12984
1. Install the spring. 2. Install the piston assembly. 3. Install the O-ring. 4. Install the servo cover.
Notice: Refer to Fastener Notice .
5. Install the servo cover bolts.
Tighten the bolts to 12 N.m (106 lb in).
6. Remove the drain pan from under the forward servo cover. 7. Adjust the jackstand in order to
raise the rear of the frame. 8. Install the frame bolts. Refer to Frame Replacement . 9. Remove the
support from the rear of the frame.
10. Install the power steering lines to the right side of the frame. 11. Install the engine mount lower
nuts. Refer to the following:
* Engine Mount Replacement for the 3.5L engine
* Engine Mount Replacement for the 3.9L engine
* Engine Mount Replacement - Right Side for the 5.3L engine
12. Install the transaxle mount lower nuts. Refer to Transmission Mount Replacement - Left Side
(See: Transmission Mount/Service and
Repair/Transmission Mount Replacement - Left Side) .
13. Install the power steering gear. Refer to Steering Gear Replacement (See: Steering and
Suspension/Steering/Steering Gear/Service and Repair) . 14. Lower the vehicle. 15. Remove the
engine support fixture.
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
16. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Notice: Do not overfill the transmission. Overfilling will result in foaming, loss of fluid, and possible
damage to the transmission.
17. Check and fill the transaxle as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent
Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent > Page 12993
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H
> Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 13003
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H >
Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E,
Slips in Gear/L/H Axle Seal Leaks
Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks
Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11-03-08-001 > Apr > 11 >
Steering - Growl Type Noise Coming from Front of Vehicle
Axle Shaft: All Technical Service Bulletins Steering - Growl Type Noise Coming from Front of
Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11-03-08-001 > Apr > 11 >
Steering - Growl Type Noise Coming from Front of Vehicle > Page 13027
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 11-03-08-001 > Apr > 11 >
Steering - Growl Type Noise Coming from Front of Vehicle > Page 13033
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Powertrain Component Views > Page 13038
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 13039
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 13040
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 13041
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-016A > Apr > 08 > A/TSlips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894
Differential: Customer Interest A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894
INFORMATION
Bulletin No.: 08-07-30-016A
Date: April 15, 2008
Subject: Diagnostic Information on MH1, MN8, MT1, M15 Transmission Slips, Will Not Shift or May
Overheat, SES/MIL May be Illuminated, DTCs P0218, P0894 Set
Models: 2006-2007 Buick Rendezvous, Terraza 2006-2008 Buick LaCrosse, Lucerne, Allure
(Canada Only) 2008 Buick LaCrosse Super, Lucerne Super, Allure Super (Canada Only)
2006-2007 Cadillac DTS 2006-2007 Chevrolet Avalanche 2500 Series, Malibu, Malibu SS, Malibu
Maxx SS, Monte Carlo, Monte Carlo SS, Silverado Classic, Suburban 2006-2008 Chevrolet
Express, Impala, Impala SS, Uplander 2006-2007 GMC Sierra Classic, Yukon XL 2500 Series
2006-2008 GMC Savana 2006-2008 Pontiac Grand Prix, Grand Prix GTP, Grand Prix GXP, G6,
Montana SV6 2006-2007 Saturn Relay
with HYDRA‐MATIC(R) 4T80‐E (MH1), 4T65‐E (M15), 4L80E (RPO
MT1) or 4L85E (RPO MN8) Automatic Transmission
Supercede:
This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number
08-07-30-016 (Section 07 - Transmission/Transaxle).
Notice:
It is critical that all internal transmission components are thoroughly cleaned and the transmission
cooler be flushed using the J 45096 transmission oil cooling system flush and flow test tool. It is
also critical that the system be flushed in both directions to capture any friction material trapped in
the cooler. Be sure to back-flush first to push material out of the cooler, following the instructions
provided with the J 45096.
The purpose of the bulletin is to provide technicians with additional diagnostic information on
transmission slips, will not shift, or may overheat conditions. DTCs P0894 or P0218 may be set on
the above transmissions.
These conditions may be caused by friction material debonding from the Torque Converter Clutch
(TCC).
If any of these conditions are observed, the friction material from the TCC may have circulated
throughout the transmission, the cooler lines, and the transmission cooler. Remove the
transmission oil pan and inspect for friction material in the filter.
If friction material is observed in the trans pan or filter, the torque converter is the possible cause
and it will be necessary to disassemble the transmission completely for a cost comparison (include
a torque converter and filter in the estimate). Refer to service bulletin 08-07-30-001 for cleaning
and inspection instructions of the valve body assembly.
After the cost comparison, either repair or replace the transmission in the most cost effective way.
If it is necessary to replace the transmission, contact the Product Quality Center (PQC) per the
most recent version of bulletin 02-07-30-029.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-016A > Apr
> 08 > A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs P0218/P0894
Differential: All Technical Service Bulletins A/T- Slips/Overheats/Won't Shift/MIL ON/DTCs
P0218/P0894
INFORMATION
Bulletin No.: 08-07-30-016A
Date: April 15, 2008
Subject: Diagnostic Information on MH1, MN8, MT1, M15 Transmission Slips, Will Not Shift or May
Overheat, SES/MIL May be Illuminated, DTCs P0218, P0894 Set
Models: 2006-2007 Buick Rendezvous, Terraza 2006-2008 Buick LaCrosse, Lucerne, Allure
(Canada Only) 2008 Buick LaCrosse Super, Lucerne Super, Allure Super (Canada Only)
2006-2007 Cadillac DTS 2006-2007 Chevrolet Avalanche 2500 Series, Malibu, Malibu SS, Malibu
Maxx SS, Monte Carlo, Monte Carlo SS, Silverado Classic, Suburban 2006-2008 Chevrolet
Express, Impala, Impala SS, Uplander 2006-2007 GMC Sierra Classic, Yukon XL 2500 Series
2006-2008 GMC Savana 2006-2008 Pontiac Grand Prix, Grand Prix GTP, Grand Prix GXP, G6,
Montana SV6 2006-2007 Saturn Relay
with HYDRA‐MATIC(R) 4T80‐E (MH1), 4T65‐E (M15), 4L80E (RPO
MT1) or 4L85E (RPO MN8) Automatic Transmission
Supercede:
This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number
08-07-30-016 (Section 07 - Transmission/Transaxle).
Notice:
It is critical that all internal transmission components are thoroughly cleaned and the transmission
cooler be flushed using the J 45096 transmission oil cooling system flush and flow test tool. It is
also critical that the system be flushed in both directions to capture any friction material trapped in
the cooler. Be sure to back-flush first to push material out of the cooler, following the instructions
provided with the J 45096.
The purpose of the bulletin is to provide technicians with additional diagnostic information on
transmission slips, will not shift, or may overheat conditions. DTCs P0894 or P0218 may be set on
the above transmissions.
These conditions may be caused by friction material debonding from the Torque Converter Clutch
(TCC).
If any of these conditions are observed, the friction material from the TCC may have circulated
throughout the transmission, the cooler lines, and the transmission cooler. Remove the
transmission oil pan and inspect for friction material in the filter.
If friction material is observed in the trans pan or filter, the torque converter is the possible cause
and it will be necessary to disassemble the transmission completely for a cost comparison (include
a torque converter and filter in the estimate). Refer to service bulletin 08-07-30-001 for cleaning
and inspection instructions of the valve body assembly.
After the cost comparison, either repair or replace the transmission in the most cost effective way.
If it is necessary to replace the transmission, contact the Product Quality Center (PQC) per the
most recent version of bulletin 02-07-30-029.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential: >
06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated
Rear Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Window
Noise When Operated
TECHNICAL
Bulletin No.: 06-08-64-033C
Date: April 29, 2008
Subject: Rubbing/Squealing/Grinding Noise When Door Glass Is Raised Or Lowered, Scratches in
Door Glass (Replace Door Glass Belt Sealing Strip)
Models: 2006-2008 Chevrolet Impala
Built Prior to November 2007
Supercede:
This bulletin is being revised to update the model years and add the build date. Please discard
Corporate Bulletin Number 06-08-64-033B (Section 08 - Body & Accessories).
Condition
Some customers may comment on a rubbing, squealing or grinding noise when opening or closing
the left or right front or rear door glass. They may also comment of scratches in the door glass.
Cause
This condition may be cause by dirt accumulating on the lip of the belt sealing strip.
Correction
Replace the door glass outer belt sealing strip with a newly designed outer belt sealing strip . Refer
to Front Side Door Window Belt Outer Sealing Strip Replacement or Rear Side Door Window Belt
Outer Sealing Strip Replacement in SI. Clean the glass with glass cleaner and if scuffs or scratches
are found it may be necessary to replace the glass as well.
Parts Information
Warranty Information
For vehicle repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential: >
06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 13060
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential: >
06-08-64-033C > Apr > 08 > Body - Front/Rear Window Noise When Operated > Page 13066
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Page 13067
Differential: Service and Repair
Final Drive Replacement
Tools Required
J 42562 Axle Removal Wedge
Removal Procedure
1. Remove the case extension housing. Refer to Case Extension Replacement (See: Extension
Housing/Service and Repair) . 2. Remove the left drive axle from the transaxle. Refer to Wheel
Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
3. Rotate the differential carrier until the end of the output shaft can be seen and the differential
pinion shaft (701) is in a horizontal position. 4. Place the J 42562 between the end of the output
shaft and the differential pinion shaft. 5. Using a hammer, hit the end of the axle removal tool in
order to compress the output shaft compression ring (509) and push the output shaft
through the differential side gear.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Page 13068
6. Remove the differential carrier (700). 7. Using snap ring pliers remove the compression ring
(509) from the output shaft.
8. Remove the output shaft (510) through the left wheel opening.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Page 13069
9. Remove the sun gear thrust bearing (698) from the differential carrier sun gear. The bearing may
be stuck to the differential carrier.
10. Remove the differential carrier sun gear (697). 11. Remove the park gear (696). 12. Remove
the internal gear thrust bearing (695) from the differential carrier internal gear. 13. Remove the sun
gear shaft (689.)
Installation Procedure
1. Assemble the sun gear thrust bearing (698), the differential carrier sun gear (697), the park gear
(696), the internal gear thrust bearing (695) and
the sun gear shaft (689) into the differential carrier (700).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Component Information > Technical Service Bulletins > Page 13070
2. Install the differential carrier into the case.
3. Install the drive axle retainer rings (509) to the output shaft (510). 4. Hold the front differential
carrier in place and carefully install the output shaft to the transmission through the left wheel
opening. 5. Install the case extension housing. Refer Case Extension Replacement (See:
Extension Housing/Service and Repair) . 6. Install left drive axle to the transaxle. Refer to Wheel
Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic
Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Transmission Fluid Filler Tube Replacement
Removal Procedure
1. Remove the transaxle oil level indicator. 2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 3. Remove the catalytic converter from the exhaust manifold. Refer to
Catalytic Converter Replacement (LS4) Catalytic Converter Replacement
(RPOs LZE/LZ4/LZ8) .
4. Remove the fluid filler tube bracket bolt. 5. Remove the fluid filler tube.
Installation Procedure
Important: Do NOT place the fluid filler tube seal on the fluid filler tube when installing the tube or
damage to the seal will result.
1. Install the fluid filler tube seal in the transaxle. 2. Position the fluid filler tube.
Notice: Refer to Fastener Notice .
3. Install the fluid filler tube bracket bolt.
Tighten the bolt to 13 N.m (115 lb in).
4. Install the catalytic converter. Refer to Catalytic Converter Replacement (LS4) Catalytic
Converter Replacement (RPOs LZE/LZ4/LZ8) . 5. Lower the vehicle.
Notice: Refer to Do Not Overfill the Transmission Notice .
6. Check and fill the transaxle as necessary. 7. Install the transaxle oil level indicator. 8. Inspect for
fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T
> Component Information > Service and Repair
Extension Housing: Service and Repair
Case Extension Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove the right
drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings
and Joints/Axle Shaft
Assembly/Service and Repair) .
4. Remove the transaxle brace. Refer to Transmission Brace Replacement (RPO LS4) (See:
Transmission Mount/Service and Repair/Transmission
Brace Replacement)Transmission Brace Replacement (RPOs LZ9/LZE) (See: Transmission
Mount/Service and Repair/Transmission Brace Replacement) .
5. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement (See:
Powertrain Management/Computers and Control
Systems/Sensors and Switches - Computers and Control Systems/Vehicle Speed Sensor/Service
and Repair) .
6. Remove the case extension housing bolts (5). 7. Remove the case extension housing (6) with
the axle seal and the O-ring (8).
Installation Procedure
1. Install the O-ring (8) to the case extension housing (6). 2. Install the case extension housing (6)
with the axle seal and the O-ring (8).
Notice: Refer to Fastener Notice .
3. Install the case extension housing bolts (5).
Tighten the bolts to 36 N.m (27 lb ft).
4. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement (See: Powertrain
Management/Computers and Control
Systems/Sensors and Switches - Computers and Control Systems/Vehicle Speed Sensor/Service
and Repair) .
5. Install the transaxle brace. Refer to Transmission Brace Replacement (RPO LS4) (See:
Transmission Mount/Service and Repair/Transmission
Brace Replacement)Transmission Brace Replacement (RPOs LZ9/LZE) (See: Transmission
Mount/Service and Repair/Transmission Brace Replacement) .
6. Install the right drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement (See: Drive
Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection (RPO LS4) Battery Negative Cable
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T
> Component Information > Service and Repair > Page 13077
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: Refer to Do Not Overfill the Transmission Notice .
9. Check and fill the transaxle as necessary.
10. Inspect for fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information
Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information
INFORMATION
Bulletin No.: 04-07-30-037E
Date: April 07, 2011
Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF)
Models:
2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008
HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION
2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo,
Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except
2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only
Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT
(MJ7/MJ8) Transmission Only Except 2008 Saturn Astra
Attention:
DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs
for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids.
Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin
Number 04-07-30-037D (Section 07 - Transmission/Transaxle).
MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING
The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle
that previously required DEXRON(R)-III for a manual transmission or transfer case should now use
P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual
transmissions and transfer cases require a different fluid. Appropriate references should be
checked when servicing any of these components.
Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid.
Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations.
Some of our customers and/or General Motors dealerships/Saturn Retailers may have some
concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and
transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for
General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the
J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with
DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as
noted above).
DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic
transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair
or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use
in automatic transmissions/transaxles.
DEXRON(R)-VI ATF
General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle
production.
Current and prior automatic transmission models that had used DEXRON(R)-III must now only use
DEXRON(R)-VI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 13082
All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with
DEXRON(R)-VI fluid.
DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas:
* These ATF change intervals remain the same as DEXRON(R)-III for the time being.
2006-2008 Transmission Fill and Cooler Flushing
Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the
machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI.
Parts Information
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 13083
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 13084
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Bottom Pan Removal (2WD) ...............................................................................................................
....................................................... 7.0L (7.4 Quarts) Complete Overhaul (2WD) ..............................
......................................................................................................................................... 9.5L (10.0
Quarts) Dry (2WD) ...............................................................................................................................
.............................................................. 12.7L (13.4 Quarts)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications > Page 13087
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID
DEXRON-VI Automatic Transmission Fluid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Page 13088
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Automatic Transmission Fluid Filter and Seal Replacement
Removal Procedure
1. Remove the oil pan (24) and the gasket (25). Refer to Oil Pan Replacement (See: Fluid
Pan/Service and Repair) . 2. Remove the filter (100). Remove the lip ring seal (101) pressed into
the case only if replacement is necessary. 3. Inspect the oil pan and the filter for the following
foreign material:
* metal particles
* clutch facing material
* rubber particles
* engine coolant
4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of
the contamination.
Installation Procedure
1. If removed, install a new seal (101).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 13092
2. Install the filter (100). 3. Install the gasket (25) and the oil pan (24). Refer to Oil Pan
Replacement (See: Fluid Pan/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting
Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line
Fitting
INFORMATION
Bulletin No.: 04-07-30-017B
Date: November 25, 2008
Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler
Fitting and Torque Converter Drain Back Check Ball Change
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks
with one of the HYDRA-MATIC(R) Automatic Transmissions shown above.
Supercede:
This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin
Number 04-07-30-017A (Section 07 - Transmission/Transaxle).
Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings
have changed and are not interchangeable with past models. The technician may find that when
replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the
transmission.
A change to the transmission cooler line fittings was implemented in production on February 1,
2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler
line fittings with the longer lead in pilot will not fit on models built before February 1, 2004.
The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2)
(3/8-18 NPSF w/check ball & 1/4-18 NPSF).
If the transmission cooler lines will not connect, then replace them with the following cooler line
fittings as appropriate with the older, shorter lead in pilot design:
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N
20793004.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second
design P/N 15264588.
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N
20793005.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second
design P/N 15264589.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page
13097
The torque specification has changed for the fittings to case. The torque has changed from 38 Nm
(28 lb ft) to 32 Nm (23 lb ft).
Tighten
Tighten the new cooler fittings to 32 Nm (23 lb ft).
The converter drain back check ball (420C) has been removed from the cooler line fitting and is
now located in the channel plate.
If you get a concern of no movement in the morning or after sitting for several hours, the cooler
check ball should be inspected.
The best way to determine where the check ball is located is to look at the cooler line fittings. The
old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check
ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler
check ball.
Parts Information
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement
Transmission Fluid Cooler Hose/Pipe Replacement
Removal Procedure
1. Disconnect the transaxle oil cooler (TOC) outlet hose from top side of the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: ) .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove the TOC
hose retainer bolt. 4. Position a drain pan below the oil cooler hoses.
5. Disconnect the TOC outlet hose from the transaxle. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and
Connection (See: ) .
6. Disconnect the TOC inlet hose from the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13100
7. Disconnect the TOC inlet hose from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
8. Disconnect the TOC hoses from the radiator support retainer. 9. Remove the TOC hoses from
the vehicle.
Installation Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Install the TOC hoses to the vehicle. 2. Connect the TOC hoses to the radiator support retainer.
3. Connect the TOC inlet hose to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection (
See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13101
4. Connect the TOC inlet hose to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection
(See: ) .
5. Connect the TOC outlet hose to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
Notice: Refer to Fastener Notice .
6. Install the TOC hose retainer and the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
7. Lower the vehicle. 8. Connect the TOC outlet hose to the top side of the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection
and Connection (See: ) .
Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid,
shift complaints, and possible damage to the transaxle.
9. Adjust the fluid level. Refer to the following procedures:
* Transmission Fluid Check (See: Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check)
* Fluid and Lubricant Recommendations
* Approximate Fluid Capacities
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13102
Fluid Line/Hose: Service and Repair Transmission Fluid Dam Replacement
Transmission Fluid Dam Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Remove the oil reservoir weir (27).
Installation Procedure
1. Install the oil reservoir weir (27). 2. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13103
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Connector Replacement
Transmission Fluid Cooler Hose/Pipe Connector Replacement
Removal Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position a drain pan
under the vehicle. 3. Remove the transaxle oil cooler hoses from the transaxle oil cooler fittings.
Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: ) . 4. Remove the transaxle oil
cooler fittings (28, 29) from the transaxle.
Installation Procedure
Notice: Refer to Fastener Notice .
Important: The correct thread engagement is critical. Crossthreaded fittings can achieve proper
tightness and still leak.
1. Install the transaxle oil cooler fittings (28, 29) to the transaxle.
Tighten the fittings to 38 N.m (28 lb ft).
2. Install the transaxle oil cooler hoses to the transaxle oil cooler fittings. Refer to Transmission
Fluid Cooler Hose/Pipe Replacement (See: ) . 3. Lower the vehicle.
Notice: Refer to Transmission Overfill Notice .
4. Adjust the fluid level. 5. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis (See: Testing and
Inspection/Component Tests and General Diagnostics/Fluid Leak
Diagnosis) .
6. Remove the drain pan from under the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13104
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.
Installation Procedure
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
* Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13105
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears
through the 3 slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the 3 retaining ring ears are seen from inside the fitting and that the retaining ring
moves freely in the fitting slots.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13106
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13107
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13108
Fluid Line/Hose: Service and Repair
Transmission Fluid Cooler Hose/Pipe Replacement
Transmission Fluid Cooler Hose/Pipe Replacement
Removal Procedure
1. Disconnect the transaxle oil cooler (TOC) outlet hose from top side of the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: ) .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove the TOC
hose retainer bolt. 4. Position a drain pan below the oil cooler hoses.
5. Disconnect the TOC outlet hose from the transaxle. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and
Connection (See: ) .
6. Disconnect the TOC inlet hose from the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13109
7. Disconnect the TOC inlet hose from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
8. Disconnect the TOC hoses from the radiator support retainer. 9. Remove the TOC hoses from
the vehicle.
Installation Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Install the TOC hoses to the vehicle. 2. Connect the TOC hoses to the radiator support retainer.
3. Connect the TOC inlet hose to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection (
See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13110
4. Connect the TOC inlet hose to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection
(See: ) .
5. Connect the TOC outlet hose to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: ) .
Notice: Refer to Fastener Notice .
6. Install the TOC hose retainer and the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
7. Lower the vehicle. 8. Connect the TOC outlet hose to the top side of the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection
and Connection (See: ) .
Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid,
shift complaints, and possible damage to the transaxle.
9. Adjust the fluid level. Refer to the following procedures:
* Transmission Fluid Check (See: Testing and Inspection/Component Tests and General
Diagnostics/Transmission Fluid Check)
* Fluid and Lubricant Recommendations
* Approximate Fluid Capacities
Transmission Fluid Dam Replacement
Transmission Fluid Dam Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13111
2. Remove the oil reservoir weir (27).
Installation Procedure
1. Install the oil reservoir weir (27). 2. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Transmission Fluid Cooler Hose/Pipe Connector Replacement
Transmission Fluid Cooler Hose/Pipe Connector Replacement
Removal Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position a drain pan
under the vehicle. 3. Remove the transaxle oil cooler hoses from the transaxle oil cooler fittings.
Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: ) . 4. Remove the transaxle oil
cooler fittings (28, 29) from the transaxle.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13112
Notice: Refer to Fastener Notice .
Important: The correct thread engagement is critical. Crossthreaded fittings can achieve proper
tightness and still leak.
1. Install the transaxle oil cooler fittings (28, 29) to the transaxle.
Tighten the fittings to 38 N.m (28 lb ft).
2. Install the transaxle oil cooler hoses to the transaxle oil cooler fittings. Refer to Transmission
Fluid Cooler Hose/Pipe Replacement (See: ) . 3. Lower the vehicle.
Notice: Refer to Transmission Overfill Notice .
4. Adjust the fluid level. 5. Inspect for fluid leaks. Refer to Fluid Leak Diagnosis (See: Testing and
Inspection/Component Tests and General Diagnostics/Fluid Leak
Diagnosis) .
6. Remove the drain pan from under the vehicle.
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13113
5. Pull the cooler line straight out from the quick connect fitting.
Installation Procedure
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
*
Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears
through the 3 slots on the fitting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13114
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the 3 retaining ring ears are seen from inside the fitting and that the retaining ring
moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13115
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) .
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13116
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill) .
2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: ) .
Important: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the
same time other wise the transaxle oil cooler will fall inside the radiator end tank.
3. Remove the oil cooler fitting from the radiator.
Installation Procedure
1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary.
Notice: Refer to Fastener Notice .
Important: The correct thread engagement is critical. Cross-threaded fittings can achieve proper
tightness and still leak.
2. Install the oil cooler fitting to the radiator
Tighten the fittings to 38 N.m (28 lb ft).
3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13117
Disconnection and Connection (See: ) .
4. Fill the cooling system. Refer to Cooling System Draining and Filling (9C1, 9C3 Static Fill)
Cooling System Draining and Filling (LZE, LZ4,
LZG, 9C1, 9C3, GE47716 Fill) Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill) .
5. Adjust the transmission fluid level. 6. Inspect for fluid leaks.
Transmission Fluid Auxiliary Cooler Inlet and Outlet Pipe Replacement
Transmission Fluid Auxiliary Cooler Inlet and Outlet Pipe Replacement
Removal Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector
Replacement .
2. Remove the auxiliary transmission oil cooler lines from the support clip (3). 3. Remove the
auxiliary transmission oil cooler lines from the fan shroud support clip. 4. Remove the inlet and
outlet auxiliary transmission oil cooler lines (1, 2) from the transmission and radiator. Refer to
Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ) .
5. Remove the inlet and outlet auxiliary transmission oil cooler lines from the auxiliary transmission
oil cooler. Refer to Transmission Fluid Auxiliary
Cooler Replacement (See: Transmission Cooler/Service and Repair) .
Installation Procedure
1. Install the inlet and outlet auxiliary transmission oil cooler lines to the auxiliary transmission oil
cooler. Refer to Transmission Fluid Auxiliary
Cooler Replacement (See: Transmission Cooler/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 13118
2. Install the inlet and outlet auxiliary transmission oil cooler lines (1, 2) to the transmission and
radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ) .
3. Install the support clip (3) to the auxiliary transmission oil cooler lines. 4. Install the auxiliary
transmission oil cooler lines to the fan shroud support clip. 5. Install the lower radiator air baffle.
Refer to Radiator Air Lower Baffle and Deflector Replacement .
Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid,
shift complaints, and possible damage to the transaxle.
6. Adjust the fluid level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications
Fluid Pan: Specifications
Oil Pan Install the 20 oil pan bolts (23). Tighten the bolts to ...............................................................
..................................................................................................................... 14 N.m (10 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications > Page 13122
Fluid Pan: Service and Repair
Oil Pan Replacement
Removal Procedure
Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using
greases other than the recommended assembly lube changes the transaxle fluid characteristics.
Using greases other than the recommended assembly lube causes undesirable shift conditions
and/or filter clogging. Use TRANSJEL(TM) J 36850 or equivalent during the assembly of this unit.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Place a drain pan
under the transaxle oil pan. 3. Remove the transaxle oil pan bolts (23) from the front and the sides
of the oil pan. 4. Loosen the rear transaxle oil pan bolts.
Notice: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or
oil leaks may occur.
5. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. 6.
Allow the fluid to drain. 7. Remove the remaining transaxle bolts (23). 8. Remove the oil pan (24)
from the automatic transmission. 9. Remove the oil pan gasket (25).
10. Inspect the oil pan and the filter for the following foreign material:
* Metal particles
* Clutch facing material
* Rubber particles
* Engine coolant
11. Determine the source of the contamination. 12. Correct the source of the contamination.
13. Inspect the oil pan flange (1) for distortion. 14. Replace the oil pan (1) if bent or distorted. Do
not attempt to straighten.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications > Page 13123
15. When service requires the removal of the bottom oil, inspect the washers on the oil pan bolts.
16. If the washer is inverted, replace the bolt and the washer.
Notice: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may
result.
17. Use solvent to clean the case. 18. Air dry the case. 19. Use solvent to clean the oil pan gasket
surfaces. 20. Air dry the oil pan gasket surfaces. 21. Remove all traces of the old gasket material.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications > Page 13124
1. Install the oil pan gasket (25). 2. Install the oil pan (24).
Notice: Refer to Fastener Notice .
3. Install the oil pan bolts (23).
Tighten the bolts to 14 N.m (10 lb ft).
4. Lower the vehicle.
Notice: Refer to Do Not Overfill the Transmission Notice .
5. Fill the transaxle. Refer to Fluid Capacity Specifications (See: Specifications/Capacity
Specifications) . 6. Place the gear selector in the PARK position. 7. Start the engine. 8. Run the
engine at a slow idle. Do NOT race the engine. 9. Adjust the fluid level.
10. Inspect for leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13129
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > Page 13130
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > Page 13131
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations > Page 13132
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Service and Repair
Fluid Pump: Service and Repair
Oil Pump Replacement
Removal Procedure
Notice: Do NOT remove the three bolts which hold the pump together.
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Remove the oil pump bolts (230, 231).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Service and Repair > Page 13136
3. Remove the oil pump (200) from the valve body (300). 4. Clean and inspect the oil pump. Refer
to Transmission Fluid Pump Disassemble (See: Service and Repair/Overhaul) and Transmission
Fluid
Pump Assemble (See: Service and Repair/Overhaul) .
Installation Procedure
1. Install the oil pump (200) to the valve body (300).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Service and Repair > Page 13137
Notice: Refer to Fastener Notice .
2. Install the oil pump bolts (230, 231).
* Tighten the nine (231) M6 X 1.0 X 85 bolts to 12 N.m (106 lb in).
* Tighten the two (230) M6 X 1.0 X 95 bolts to 16 N.m (12 lb ft).
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
engine control module (ECM), powertrain control module (PCM) or transmission control module
(TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP
values are learned. Reset the TAP values. Refer to Transmission Adaptive Functions (See:
Description and Operation/Transmission Adaptive Functions) .
3. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
INFORMATION
Bulletin No.: 01-07-30-042F
Date: February 05, 2010
Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise
Models:
2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3
2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32,
M70)
Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission.
Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle).
Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin
05-07-30-012.
Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift.
During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift
can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same
torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band
applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in
the transfer case.
This is a normal condition. No repairs should be attempted.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > Page 13142
Output Shaft: Service and Repair
Output Shaft Replacement
Tool Required
J 42562 Axle Removal Wedge
Removal Procedure
1. Remove the case extension housing. Refer to Case Extension Replacement (See: Extension
Housing/Service and Repair) . 2. Remove the left drive axle from the transaxle. Refer to Wheel
Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
3. Rotate the differential carrier until the end of the output shaft can be seen and the differential
pinion shaft (701) is in a horizontal position. 4. Place the J 42562 between the end of the output
shaft and the differential pinion shaft. 5. Using a hammer, hit the end of the axle removal tool in
order to compress the output shaft compression ring (509) and push the output shaft
through the differential side gear.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > Page 13143
6. Remove the differential carrier (700). 7. Using snap ring pliers remove the compression ring
(509) from the output shaft. 8. Remove the output shaft through the left wheel opening.
9. Inspect the output shaft (510) for the following:
* Stripped splines
* Damaged retainer ring groove
* Damaged bushing journals
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > Page 13144
1. Install the drive axle retainer rings (509) to the output shaft (510). 2. Hold the front differential
carrier in place and carefully install the output shaft (510) to the transmission through the left wheel
opening. Extend the
output shaft through the differential side gear.
3. Install the case extension housing. Refer to Case Extension Replacement (See: Extension
Housing/Service and Repair) . 4. Install the left drive axle to the transaxle. Refer to Wheel Drive
Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 13148
Pressure Regulating Solenoid: Service and Repair
Pressure Control Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the pressure control solenoid (PCS) electrical connector. 3. Remove the PCS
retaining clip (314E).
4. Remove the PCS (322).
Installation Procedure
1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical
connector. 4. Install the case side cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views > Page 13154
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Page 13155
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Page 13156
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Page 13157
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 13166
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 13172
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 13173
Seals and Gaskets: By Symptom
Technical Service Bulletin # 01-07-30-032E Date: 080929
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 13174
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 01-07-30-032E Date: 080929
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 13175
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left
Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Left
Front Wheel Drive Shaft Seal Replacement - Left Side
Tools Required
* J 34115 Left Side Axle Seal Installer
* J 37292-B Axle Seal Protector
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the left front
tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair)
.
3. Remove the left stabilizer shaft link from the left lower control arm. Refer to Stabilizer Shaft Link
Replacement (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension) .
4. Remove the left tie rod end from the left steering knuckle. Refer to Steering Knuckle
Replacement (See: Steering and Suspension/Steering/Front
Steering Knuckle/Service and Repair/Front Suspension) .
5. Remove the left lower ball joint from the left steering knuckle. Refer to Steering Knuckle
Replacement (See: Steering and
Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Suspension) .
6. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement (See:
Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
7. Secure the left drive axle to the left steering knuckle and the strut. 8. Use a flat bladed
screwdriver or a suitable tool to remove the oil seal (409) from the transaxle side case (401).
Installation Procedure
1. Lubricate the seal lip with transaxle fluid.
Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact
any portion of the seal lip surface.
2. Install J 37292-B in the seal (409).
3. Use J 34115 to install the new seal. 4. Remove the J 37292-B . 5. Install the drive axle to the
transaxle. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle
Shaft
Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left > Page 13178
6. Install the left lower ball joint to the left steering knuckle. Refer to Steering Knuckle Replacement
(See: Steering and Suspension/Steering/Front
Steering Knuckle/Service and Repair/Front Suspension) .
7. Install the left tie rod end to the left steering knuckle. Refer to Steering Knuckle Replacement
(See: Steering and Suspension/Steering/Front
Steering Knuckle/Service and Repair/Front Suspension) .
8. Install the left stabilizer shaft link to the left lower control arm. Refer to Stabilizer Shaft Link
Replacement (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension) .
9. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) .
10. Lower the vehicle.
Notice: Refer to Do Not Overfill the Transmission Notice .
11. Adjust the fluid level. 12. Inspect for proper completion of the repairs. 13. Inspect for proper
fluid level. 14. Inspect for fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left > Page 13179
Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Right
Front Wheel Drive Shaft Seal Replacement - Right Side
Tools Required
* J 6125-B Slide Hammer
* J 23129 Universal Seal Remover
* J 29130 Axle Shaft Seal Installer
* J 37292-B Axle Seal Protector
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels
and Tires/Service and Repair
).
3. Remove the right stabilizer shaft link from the right lower control arm. Refer to Stabilizer Shaft
Link Replacement (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension) .
4. Remove the right tie rod end from the right steering knuckle. Refer to Steering Knuckle
Replacement (See: Steering and
Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Suspension) .
5. Remove the right lower ball joint from the right steering knuckle. Refer to Steering Knuckle
Replacement (See: Steering and
Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Suspension) .
6. Remove the right drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement (See:
Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
7. Secure the right drive axle to the right steering knuckle and the strut. 8. Use the J 6125-B (3) and
the J 23129 (4) to remove the oil seal (1) from the extension housing (2).
Installation Procedure
1. Lubricate the seal lip with transaxle fluid. 2. Install J 37292-B in the seal (4).
3. Use J 29130 to install the new seal (4). 4. Remove the J 37292-B .
Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact
any portion of the seal lip surface.
5. Install the drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement (See: Drive
Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left > Page 13180
6. Install the right lower ball joint to the right steering knuckle. Refer to Steering Knuckle
Replacement (See: Steering and
Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Suspension) .
7. Install the right tie rod end to the right steering knuckle. Refer to Steering Knuckle Replacement
(See: Steering and Suspension/Steering/Front
Steering Knuckle/Service and Repair/Front Suspension) .
8. Install the right stabilizer shaft link to the right steering knuckle. Refer to Stabilizer Shaft Link
Replacement (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension) .
9. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) .
10. Lower the vehicle.
Notice: Refer to Transmission Overfill Notice .
11. Check and fill the transaxle fluid as necessary. 12. Inspect for fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page
13186
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13187
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13188
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13189
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13194
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 13195
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page
13200
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 13201
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 13202
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
> Page 13208
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 13209
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature
Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature
Sensor Replacement > Page 13212
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature
Sensor Replacement > Page 13213
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Fluid Pan/Service and Repair) . 8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-007B > Jun
> 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-007B > Jun
> 09 > A/T - Key Cannot Be Removed/No Shift From Park > Page 13223
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
08-07-30-007B > Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park > Page 13229
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift
Interlock Solenoid: > 08-08-110-007 > Mar > 08 > Interior - Driver's Power Window Switch Sticks/Binds
Power Window Switch: All Technical Service Bulletins Interior - Driver's Power Window Switch
Sticks/Binds
TECHNICAL
Bulletin No.: 08-08-110-007
Date: March 31, 2008
Subject: Driver Side Window Switch Sticks (Replace Window Switch Bezel and/or Window Switch)
Models: 2008 Chevrolet Impala
Condition
Some customers may comment that driver side window switch does not operate the window
correctly or the switch sticks.
Cause
This condition may be caused because the bezel trim has excess flashing, causing the switch to
bind in the bezel. Damage to the window switch may result from this condition.
Correction
Replace the bezel and/or window switch. Refer to Front Side Door Window Switch Bezel
Replacement in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Page 13240
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: To prevent component damage, DO NOT use metal tools to remove the trim.
Important: Use only a plastic trim tool to lift the shift lever bezel or trim plate. Do not use any tool
between the shift lever bezel or trim plate and the shifter.
2. Remove the center console. Refer to Front Floor Console Replacement (Impala) . 3. Disconnect
the automatic transaxle shift lock actuator electrical connector (1). 4. Remove both ends of the
automatic transaxle shift lock actuator from the pivot points.
Installation Procedure
1. Install both ends of the automatic transaxle shift lock actuator to the pivot points. 2. Connect the
automatic transaxle shift lock actuator electrical connector (1). 3. Install the center console. Refer
to Front Floor Console Replacement (Impala) . 4. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > 4T65-E - Automatic Transaxle
Shift Solenoid: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13246
Shift Solenoid: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
In the Center Console - Floor Shifter
In the Center Console - Floor Shifter
1 - Floor Shifter 2 - A/T Shift Lock Control Solenoid
Steering Column Components - Column Shift
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13247
Lower Steering Column Components
1 - Automatic Transmission Shift Lock Control Solenoid 2 - Steering Column
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13250
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13251
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13252
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13253
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13366
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13367
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13368
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13369
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13370
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13371
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13372
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13373
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13374
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13375
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13376
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 13377
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (1-2 SS) Valve
2-3 Shift Solenoid (2-3 SS) Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 13378
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement
Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement
1-2 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining
clip (314D)
4. Remove the 1-2 shift solenoid (315A).
Installation Procedure
1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3.
Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 13381
Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining
clip (314C).
4. Remove the 2-3 shift solenoid (315B) and the O-ring (316).
Installation Procedure
1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining
clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover.
Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control
Valve Body Cover
Replacement) .
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be
affected as new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 08-07-30-007B > Jun > 09 > A/T
- Key Cannot Be Removed/No Shift From Park
Shifter A/T: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Technical Service Bulletins > Customer Interest for Shifter A/T: > 08-07-30-007B > Jun > 09 > A/T
- Key Cannot Be Removed/No Shift From Park > Page 13390
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 08-07-30-007B >
Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Shifter A/T: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 08-07-30-007B >
Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park > Page 13396
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > Shift Lever Replacement
Shifter A/T: Service and Repair Shift Lever Replacement
Shift Lever Replacement
Removal Procedure
Caution: Refer to SIR Caution .
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Slide the shift lever seal (2) up
the shift lever (4). 3. If necessary, remove the steering column trim covers. Refer to Steering
Column Trim Covers Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Covers
Replacement) .
4. Disconnect the shift lever connector at the base of the column. 5. Remove the shift lever screw
(3) from the shift lever assembly (4). 6. Remove the shift lever and seal from the linear shift
assembly.
Important: The shift lever seal must be removed by sliding the shift lever seal towards the narrow
section of the shift lever.
7. Remove the shift lever seal (2) from the shift lever (4).
Installation Procedure
Important: The shift lever seal must be installed to the narrow end of the shift lever.
1. Install the shift lever seal (2) onto the shift lever assembly (4). 2. Install the shift lever assembly
(4) to linear shift assembly.
Notice: Refer to Fastener Notice .
3. Install the shift lever screw (3) into the shift lever assembly (4).
Tighten the screw to 20 N.m (15 lb ft).
4. Slide the shift lever seal (2) down the shift lever assembly (4). 5. Align the shift lever seal into the
steering column trim covers. 6. If necessary, install the steering column trim covers. Refer to
Steering Column Trim Covers Replacement (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Column Trim Covers
Replacement) .
7. Enable the SIR system. Refer to SIR Disabling and Enabling .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > Shift Lever Replacement > Page 13399
Shifter A/T: Service and Repair 4T65-E - Automatic Transaxle
Transmission Control Replacement
Removal Procedure
1. Remove the console trim plate . Refer to Front Floor Console Replacement (Impala) . 2. Remove
the console wiring harness.
3. Remove the console shift control wiring harness. 4. Remove the automatic transaxle range
selector cable. Refer to Range Selector Lever Cable Replacement (See: Shift Linkage/Shift
Cable/Service
and Repair) .
5. Disconnect the lightbulb and the retainer from the shiftier.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > Shift Lever Replacement > Page 13400
6. Remove the console shift control retaining nuts. 7. Remove the console shift control assembly
from the vehicle.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > Shift Lever Replacement > Page 13401
1. Install the console shift control into the vehicle.
Notice: Refer to Fastener Notice .
2. Install the console shift control retaining nuts.
Tighten the console shift control retaining nuts to 24 N.m (18 lb ft).
3. Install the automatic transaxle range selector cable. Refer to Range Selector Lever Cable
Replacement (See: Shift Linkage/Shift Cable/Service
and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > Shift Lever Replacement > Page 13402
4. Install the console shift control wiring harness. 5. Install the console wiring harness. 6. Install the
console trim plate. Refer to Front Floor Console Replacement (Impala) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Range Selector Lever Cable Adjustment
Adjustment Procedure
1. Apply the parking brake and ensure the vehicle is not running.
2. Ensure that the shift control assembly is in the park (P) position. 3. Pull back the white plastic
cover (1) on the center connector.
4. Pull up on the center tabs of the lock button (2).
Important: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the
shift cable end (2) during this procedure.
5. Release the shift cable end (2) and allow the blue spring to tension/adjust the shift cable system.
6. Pull the white cover (3) on the shift cable end (1) back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13407
7. Push the natural colored lock button (2) down to engage the locking teeth on the shift cable end
(1).
8. Release the white cover (1).
9. Verify the white cover (1) conceals the natural colored lock (2).
10. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be
readjusted. 11. Test the transmission for proper shift operation. 12. If all of the gear positions
cannot be achieved, the shift cable must be readjusted.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13408
Shift Cable: Service and Repair
Range Selector Lever Cable Replacement
Removal Procedure Caution: Refer to Automatic Transmission Range Selector Cable Caution .
1. Remove the air cleaner outlet duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
2. Remove the automatic transaxle range selector cable from the wiring harness clip or strap.
3. Remove the automatic transaxle range selector cable retainer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13409
4. Remove the automatic transaxle range selector cable from the automatic transaxle range
selector lever. 5. Remove the automatic transaxle range selector cable from the automatic
transaxle range selector cable bracket.
6. If equipped with a floor console, remove the front floor console. Refer to Front Floor Console
Replacement (Impala) . 7. Pull the carpet back to expose the automatic transaxle range selector
cable. Refer to Floor Panel Carpet Replacement (Impala) . 8. Remove the automatic transaxle
range selector cable retainer from the console shift control.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13410
9. Remove the automatic transaxle range selector cable from the console shift control.
10. Remove the automatic transaxle range selector cable from the console shift control bracket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13411
11. If equipped with a steering column shift control, remove the left knee bolster bracket. Refer to
Driver Knee Bolster Bracket Replacement . 12. Remove the automatic transmission range selector
cable from the shift control lever.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13412
13. Install a piece of mechanics wire to the end of the automatic transmission range selector cable.
14. Remove the automatic transmission range selector cable through the hole in the cowl.
Installation Procedure Caution: Refer to Automatic Transmission Range Selector Cable Caution .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13413
1. Install the automatic transmission range selector cable through the hole in the cowl. 2. Remove
the mechanics wire from the end of the automatic transmission range selector cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13414
3. If equipped with a steering column shift control, install the automatic transmission range selector
cable to the shift control lever. 4. Install the left knee bolster bracket. Refer to Driver Knee Bolster
Bracket Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13415
5. If equipped with a floor console shift control, install the automatic transaxle range selector cable
to the console shift control bracket. 6. Install the automatic transaxle range selector cable to the
console shift control.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13416
7. Install the automatic transaxle range selector cable retainer to the console shift control. 8. Install
the carpet into position. Refer to Floor Panel Carpet Replacement (Impala) . 9. Install the Front
Floor Console. Refer to Front Floor Console Replacement (Impala) .
10. Properly route and position the automatic transmission range selector cable.
11. Install the automatic transaxle range selector cable to the automatic transaxle range selector
cable bracket. 12. Install the automatic transaxle range selector cable to the automatic transaxle
range selector lever.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13417
13. Install the automatic transaxle range selector cable retainer.
14. Place the transaxle in the Neutral position. 15. Place the shift control in the Neutral position. 16.
Connect each cable section to the following before connecting the two cable sections.
* Insert the metal end fitting of the shift control cable into the transaxle cable end.
* Use the molded end fittings to push the metal end fitting of the shift control cable and the
transaxle cable end together until the metal post snaps into place.
17. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end
fitting. 18. Line up the end fittings so they slide together until you feel the parts cam together and
lock.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13418
19. Depress the adjuster clip completely. This locks the cable into its adjusted service position. 20.
Pull the conduit in the opposite direction to assure full system adjustment of the shift cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13419
Important: The horseshoe clip with the tab is flush when fully engaged.
21. Ensure the conduit is fully engaged.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13420
22. The horseshoe clip with the tab is not flush when not fully engaged.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > Page 13421
23. Install the automatic transaxle range selector cable to the wiring harness clip or strap. 24.
Adjust the automatic transaxle range selector cable. Refer to Range Selector Lever Cable
Adjustment (See: Adjustments) . 25. Install the air cleaner outlet duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information
Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information
INFORMATION
Bulletin No.: 01-07-30-010C
Date: May 12, 2008
Subject: Automatic Transmission/Transaxle Torque Converter Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009
and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75)
2009 and Prior Saab 9-7X
with ALL Automatic Transmissions and Transaxles
Supercede:
This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin
Number 01-07-30-010B (Section 07 - Transmission/Transaxle).
The purpose of this bulletin is to help technicians determine when a torque converter should be
replaced. Below is a list of general guidelines to follow.
The converter should NOT be replaced if the following apply:
^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition
(i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical
concern within the torque converter.
^ The fluid has an odor or is discolored but no evidence of metal contamination.
^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is
not harmful to the torque converter.
^ The vehicle has been exposed to high mileage.
^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter
(RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither
the converter nor the front pump assembly should be replaced.
The torque converter should be replaced under any of the following conditions:
^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic
diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the
converter bushing and/or internal 0-ring may be damaged.
^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support
and bearing or metal chips/debris in the converter.
^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines.
^ External leaks in the hub weld area lug weld or closure weld.
^ Converter pilot is broken damaged or fits poorly into the crankshaft.
^ The converter hub is scored or damaged.
^ The transmission oil is contaminated with engine coolant engine oil or water.
^ If excessive end play is found after measuring the converter for proper end play (refer to Service
Manual).
^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit
are worn or damaged. This indicates that the material came from the converter.
^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by
following Converter Vibration Procedures.
^ Blue converter or dark circular ring between lugs. This condition will also require a complete
cleaning of the cooler and a check for adequate flow
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 13426
through the cooler.
^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at
idle. The noise is gone in Neutral and Park.
^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY).
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Page 13427
Torque Converter: Service and Repair
Flywheel to Torque Converter Bolt Replacement
Tools Required
J 37096 Flywheel Holder
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the torque
converter cover bolts. 3. Remove the torque converter covers.
4. Install the J 37096 in order to gain access to the torque converter bolts and to prevent the
flywheel from turning.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Page 13428
5. Remove the flywheel to torque converter bolts.
Installation Procedure
1. Install the J 37096 in order to gain access to the torque converter bolts and to prevent the
flywheel from turning.
Notice: Refer to Fastener Notice .
2. Install the flywheel to torque converter bolts.
Tighten the bolts to 63 N.m (46 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Page 13429
3. Install the torque converter covers. 4. Install the torque converter cover bolts.
Tighten the bolts to 10 N.m (89 lb in)
5. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line
Fitting
Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check
Valve/Cooler Line Fitting
INFORMATION
Bulletin No.: 04-07-30-017B
Date: November 25, 2008
Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler
Fitting and Torque Converter Drain Back Check Ball Change
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks
with one of the HYDRA-MATIC(R) Automatic Transmissions shown above.
Supercede:
This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin
Number 04-07-30-017A (Section 07 - Transmission/Transaxle).
Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings
have changed and are not interchangeable with past models. The technician may find that when
replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the
transmission.
A change to the transmission cooler line fittings was implemented in production on February 1,
2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler
line fittings with the longer lead in pilot will not fit on models built before February 1, 2004.
The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2)
(3/8-18 NPSF w/check ball & 1/4-18 NPSF).
If the transmission cooler lines will not connect, then replace them with the following cooler line
fittings as appropriate with the older, shorter lead in pilot design:
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N
20793004.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second
design P/N 15264588.
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N
20793005.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second
design P/N 15264589.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line
Fitting > Page 13434
The torque specification has changed for the fittings to case. The torque has changed from 38 Nm
(28 lb ft) to 32 Nm (23 lb ft).
Tighten
Tighten the new cooler fittings to 32 Nm (23 lb ft).
The converter drain back check ball (420C) has been removed from the cooler line fitting and is
now located in the channel plate.
If you get a concern of no movement in the morning or after sitting for several hours, the cooler
check ball should be inspected.
The best way to determine where the check ball is located is to look at the cooler line fittings. The
old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check
ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler
check ball.
Parts Information
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch, A/T > Component Information > Diagrams
Torque Converter Clutch: Diagrams
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13443
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13444
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13445
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13446
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13447
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13448
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13449
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13450
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13451
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13452
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13453
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13454
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13455
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13456
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13457
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13458
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13459
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13460
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13461
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13462
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13463
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13464
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13465
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13466
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13467
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13468
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13469
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13470
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13563
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13564
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 13565
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch Solenoid Replacement
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid
Replacement
Torque Converter Clutch Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Remove the TCC
solenoid retaining clip (314) 4. Remove the TCC solenoid (315).
Installation Procedure
1. Install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the
TCC solenoid electrical connector. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
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Page 13572
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width
Modulation Solenoid Replacement
Torque Converter Clutch Pulse Width Modulation Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect and reposition the electrical connectors from the following:
* If equipped internal mode switch
* 2-3 Shift solenoid valve assembly (315B)
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
3. Remove the oil pump bolts (230, 231).
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Page 13573
4. Remove the oil pump (200) from the valve body (300).
5. Disconnect the torque converter clutch pulse width modulation (TCC PWM) solenoid electrical
connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM
solenoid (334).
Installation Procedure
1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3.
Connect the TCC PWM solenoid electrical connector.
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Page 13574
4. Install the oil pump (200) to the valve body (300).
Notice: Refer to Fastener Notice .
5. Install the oil pump body and cover bolts (230, 230).
* Tighten the nine bolts (231) to 12 N.m (106 lb in).
* Tighten the two bolts (230) to 16 N.m (12 lb ft).
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Page 13575
6. Reposition and connect the electrical connectors to the following:
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
* 2-3 Shift solenoid valve assembly (315B)
* If equipped internal mode switch
7. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Cover > Component Information > Service and Repair
Torque Converter Cover: Service and Repair
Torque Converter Cover Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the torque converter cover bolts. 3. Remove the torque converter covers.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Cover > Component Information > Service and Repair > Page 13579
Important: If equipped with 5.3L V8-The tab must be on the engine side of the engine oil pan bolt.
1. Install the torque converter covers.
Notice: Refer to Fastener Notice .
2. Install the torque converter cover bolts.
Tighten the bolts to 10 N.m (89 lb in).
3. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush
Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush
INFORMATION
Bulletin No.: 02-07-30-052G
Date: March 02, 2011
Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow(R)
Models:
2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010
HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle).
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J
35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and
DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled
through the transmission oil cooling system. High-pressure air is automatically injected into the fluid
stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris.
In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil
cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along
with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles
and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel
has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material
that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum
evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can
be used for verification of flow test results.
Current essential cooler line adapters are used to connect the J 45096 to the automatic
transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and
light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo).
The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership
personnel with a barbed hose connector and rubber hose obtained locally. The
Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different
than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic
transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the
flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the
Vibe's/Wave's/Aveo's transmission fluid.
Notice
Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure.
The required minimum ATF oil flow rate reading is directly related to the supply oil temperature.
Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of
the ATF in the supply vessel.
Helpful Hints for Maintaining the Temperature at or above 18°C (65°F)
Important
- The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It
is recommended to store the J 45096 in an area of the dealership where the room temperature
remains at or above 18°C (65°F) when not in use.
- Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil
dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the
supply reservoir. Inserting a heater will damage the check valve and the subsequent repair
expense would be the dealer's responsibility.
- A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system
flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110
volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a
thermostat to hold a constant temperature.
Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room
where the temperature is maintained at or above 18°C (65°F).
Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J
45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is
maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the
machine on
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each repair.
With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of
time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the
reservoir.
Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the
reservoir to the rays of the warm sun.
Flush / Flow Test Procedure
Important All labor operations that include removal of the transmission from the vehicle and require
the transmission oil pan or transmission side cover to be removed include labor time to flush the
transmission oil cooler system.
Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the
appropriate procedure.
Important The J 45096 can be used to flush the transmission oil cooler system on an Allison
equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission
Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure.
Machine Displays
After completion of the flush and flow test, the following information is to be recorded on the repair
order. This information is displayed on the Transmission Cooling System Service Tool, J 45096,
Transflow(R) machine when the dial is in the code position.
- Tested flow rate (displayed in Gallons Per Minute (GPM)
- Temperature (displayed is degrees Fahrenheit)
- Cycle number (a number)
- Seven digit Alpha/Numeric flow code (i.e. A10DFB2)
Warranty Information
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts)
of DEXRON(R)VI transmission fluid. The amount
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of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the
repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be
shown in the Parts Section of the warranty claim document.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card,
entered in the warranty claim labor operation Flush Code additional field (when available) and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
Disclaimer
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Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination
Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 13587
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > Page 13588
Transmission Cooler: Service and Repair
Transmission Fluid Auxiliary Cooler Replacement
Removal Procedure
Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to
prevent damage or wear which may cause fluid loss.
1. Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector
Replacement . 2. Remove the auxiliary transaxle oil cooler bolt from the upper radiator support. 3.
Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement
.
4. Remove the auxiliary transaxle oil cooler bolts from the lower radiator support. 5. Remove the
inlet and outlet auxiliary transmission oil cooler lines from the support clips. 6. Lower the auxiliary
transaxle oil cooler below the front bumper. 7. Remove the inlet and outlet auxiliary transaxle oil
cooler hoses from the auxiliary transaxle oil cooler. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and
Repair) .
8. Remove the auxiliary transaxle oil cooler.
Installation Procedure
1. Install the inlet and outlet auxiliary transaxle oil cooler hoses to the auxiliary transaxle oil cooler.
Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair) .
2. Install the auxiliary transaxle oil cooler to the vehicle. 3. Install the inlet and outlet auxiliary
transmission oil cooler lines to the support clips.
Notice: Refer to Fastener Notice .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > Page 13589
4. Install the auxiliary transaxle oil cooler bolts to the lower radiator support.
Tighten the bolts to 10 N.m (89 lb in).
5. Install the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement
. 6. Install the auxiliary transaxle oil cooler bolt to the upper radiator support.
Tighten the bolt to 25 N.m (18 lb ft).
7. Install the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement
. 8. Adjust the fluid level.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13594
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Locations > Page 13595
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Testing and Inspection
Transmission Mount: Testing and Inspection
Transmission Mount Inspection
Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that
spans the width of the oil pan bottom between the oil pan and the jack support.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Important: Before replacing any transmission/transaxle mount due to suspected fluid loss, verify
that the source of the fluid is the transmission/transaxle mount, not the engine,
transmission/transaxle or accessories.
2. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle
mount and create slight tension in the rubber.
3. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the
transmission/transaxle mount if the
transmission/transaxle mount exhibits any of the following conditions:
* The hard rubber surface is covered with heat check cracks.
* The rubber is separated from the metal plate of the transmission/transaxle mount.
* The rubber is split through the center of the transmission/transaxle mount.
* If the transaxle needs replaced. Refer to Transmission Mount Replacement - Left Side (See:
Service and Repair/Transmission Mount Replacement - Left Side) .
4. If there is movement between the metal plate of the transmission/transaxle mount and its
attaching points, lower the transmission/transaxle on the
transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount
to the frame or transmission/transaxle mount bracket. Refer to Transmission Mount Replacement Left Side (See: Service and Repair/Transmission Mount Replacement - Left Side) .
5. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > Transmission Brace Replacement
Transmission Mount: Service and Repair Transmission Brace Replacement
Transmission Brace Replacement (RPO LS4)
Automatic Transmission Brace Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > Transmission Brace Replacement > Page 13601
Transmission Mount: Service and Repair Transmission Mount Bracket Replacement - Left Side
Transmission Mount Bracket Replacement - Left Side (RPO LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > Transmission Brace Replacement > Page 13602
Transmission Mount: Service and Repair Transmission Mount Replacement - Left Side
Transmission Mount Replacement - Left Side
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the left tire
and wheel assembly. 3. Remove the left engine splash shield. Refer to Engine Splash Shield
Replacement (Right) Engine Splash Shield Replacement (Left) . 4. Position a transmission jack
under the transaxle.
5. Remove the transaxle mount upper nuts from the transaxle bracket. 6. Carefully raise the
transaxle assembly.
7. Remove the transaxle mount lower nuts from the frame. 8. Remove the transaxle mount from the
frame.
Installation Procedure
1. Position the transaxle mount to the frame.
Notice: Refer to Fastener Notice .
2. Install the transaxle mount lower nuts to the frame.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > Transmission Brace Replacement > Page 13603
Tighten the transaxle mount lower nuts to 63 N.m (46 lb ft).
3. Lower the transaxle so the transaxle mount studs install into the transaxle bracket.
4. Install the transaxle mount upper nuts to the transaxle mount.
Tighten the transaxle mount upper nuts to 47 N.m (35 lb ft).
5. Remove the transmission jack from the transaxle. 6. Install the left engine splash shield. Refer to
Engine Splash Shield Replacement (Right) Engine Splash Shield Replacement (Left) . 7. Install the
left wheel and tire assembly. 8. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair
Transmission Pressure Test Port: Service and Repair
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13611
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 13612
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 13613
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Valve Body/Service and Repair/Control Valve Body Cover
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > 4T65-E - Automatic Transaxle > Page 13619
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > Page 13620
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature Sensor Replacement
> Page 13623
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Fluid Temperature Sensor Replacement
> Page 13624
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Fluid Pan/Service and Repair) . 8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842
Valve Body: Customer Interest A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842
INFORMATION
Bulletin No.: 08-07-30-002A
Date: March 12, 2008
Subject: Information On 4T65-E MN7, M15 and M76 Front Wheel Drive Automatic Transmission
Valve Body Reconditioning, DTCs P0741, P0742, P0757, P842, Harsh Shifts or Slips
Models
Supercede:
This bulletin is being updated to include Related Service Document information. Please discard
Corporate Bulletin Number 08-07-30-002 (Section 07 - Transmission/Transaxle).
The following new service information will aid technicians in providing easy to follow valve body
reconditioning instructions and new illustrations to simplify reassembly of the valve body.
Related Service Document
Corporate Bulletin Number 02-07-30-013 : Incorrect Transmission Shifts, Poor Engine
Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck
Off/On, DTCs P0757 P0741 P0742 P0730 P0756.
Important:
If valve body cleaning is not required, DO NOT disassemble bores unless it is necessary to verify
movement of valves.
Inspection Procedure
1. Using the exploded views below inspect each bore for freedom of valve(s) movement and
evidence of debris. Pay particular attention to those valves related to the customer's concern.
2. Verify movement of the valves in their normal installed position. Valves may become restricted
during removal or installation. This is normal due to small tolerances between the valves and
bores.
3. If a valve is restricted and cannot be corrected by cleaning the valve and bore replace the valve
body. Describe the restricted valve on the repair order.
Notice:
Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast)
side of the valve body. Otherwise the solenoids will bind against the transmission case as the valve
body bolts are tightened and damage may occur.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13633
Disassembly/Reassembly
1. If a valve is restricted by a metal burr from machining that bore remove the valve and burr then
inspect movement in the valve's normal position. If no other debris or restrictions are found
reassemble the valve body and install in the transmission.
2. If the valve body has been contaminated with debris from another transmission component
failure disassemble all bores for complete cleaning of all valve body components. If possible keep
individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin
for a positive identification and location of individual parts:
^ Left Side Control Valve Body Assembly
^ Right Side Control Valve Body Assembly
^ Control Valve Body Assembly Chart Valve Springs and Bore Plugs
Caution:
Use appropriate eye protection when cleaning the valve body to prevent injury.
3. Using GM Brake Clean or equivalent in a safe and clean environment (clean aluminum pan)
clean the valve body and dry it with compressed air.
4. Clean individual valve body components with GM Brake Clean or equivalent. Coat each valve
with clean ATF and reassemble in each bore. Check each valve for free movement during
assembly of each bore.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13634
Left Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13635
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13636
Right Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13637
1997-2000 M.Y. Only - Right Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13638
Valve Body Spring and Bore Plug Chart (Metric)
Valve Body Spring and Bore Plug Chart (Inch)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh
Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13639
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H >
Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842
Valve Body: All Technical Service Bulletins A/T - Harsh Shifts/Slipping/DTCs
P0741/P0742/P0757/P842
INFORMATION
Bulletin No.: 08-07-30-002A
Date: March 12, 2008
Subject: Information On 4T65-E MN7, M15 and M76 Front Wheel Drive Automatic Transmission
Valve Body Reconditioning, DTCs P0741, P0742, P0757, P842, Harsh Shifts or Slips
Models
Supercede:
This bulletin is being updated to include Related Service Document information. Please discard
Corporate Bulletin Number 08-07-30-002 (Section 07 - Transmission/Transaxle).
The following new service information will aid technicians in providing easy to follow valve body
reconditioning instructions and new illustrations to simplify reassembly of the valve body.
Related Service Document
Corporate Bulletin Number 02-07-30-013 : Incorrect Transmission Shifts, Poor Engine
Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck
Off/On, DTCs P0757 P0741 P0742 P0730 P0756.
Important:
If valve body cleaning is not required, DO NOT disassemble bores unless it is necessary to verify
movement of valves.
Inspection Procedure
1. Using the exploded views below inspect each bore for freedom of valve(s) movement and
evidence of debris. Pay particular attention to those valves related to the customer's concern.
2. Verify movement of the valves in their normal installed position. Valves may become restricted
during removal or installation. This is normal due to small tolerances between the valves and
bores.
3. If a valve is restricted and cannot be corrected by cleaning the valve and bore replace the valve
body. Describe the restricted valve on the repair order.
Notice:
Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast)
side of the valve body. Otherwise the solenoids will bind against the transmission case as the valve
body bolts are tightened and damage may occur.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13649
Disassembly/Reassembly
1. If a valve is restricted by a metal burr from machining that bore remove the valve and burr then
inspect movement in the valve's normal position. If no other debris or restrictions are found
reassemble the valve body and install in the transmission.
2. If the valve body has been contaminated with debris from another transmission component
failure disassemble all bores for complete cleaning of all valve body components. If possible keep
individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin
for a positive identification and location of individual parts:
^ Left Side Control Valve Body Assembly
^ Right Side Control Valve Body Assembly
^ Control Valve Body Assembly Chart Valve Springs and Bore Plugs
Caution:
Use appropriate eye protection when cleaning the valve body to prevent injury.
3. Using GM Brake Clean or equivalent in a safe and clean environment (clean aluminum pan)
clean the valve body and dry it with compressed air.
4. Clean individual valve body components with GM Brake Clean or equivalent. Coat each valve
with clean ATF and reassemble in each bore. Check each valve for free movement during
assembly of each bore.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13650
Left Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13651
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13652
Right Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13653
1997-2000 M.Y. Only - Right Side Control Valve Body Assembly
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13654
Valve Body Spring and Bore Plug Chart (Metric)
Valve Body Spring and Bore Plug Chart (Inch)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A >
Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 13655
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan >
09 > A/T Control - DTC P0756 Diagnostic Tips
Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 13661
Valve Body: Locations
Component Location
Ball Check Valves
Ball Check Valves
1 - TCC Apply-Release 2 - 2nd-2nd Clutch 3 - Input Clutch-PRN 4 - 3rd Clutch-Lo/1st 5 Reverse-Reverse Servo Large 6 - D4-Servo Apply 7 - Lo-Lo/1st 8 - D2-Manual 2-1 Servo Feed 9 3rd-3rd Clutch 10 - Line-Lo/1st Gear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement
Valve Body: Service and Repair Control Valve Body Cover Replacement
Control Valve Body Cover Replacement
Tools Required
J 36850 Transjel Lubricant
Removal Procedure
1. Remove the engine site shield. Refer to the following:
* Intake Manifold Cover Replacement for the 3.5L engine
* Intake Manifold Cover Replacement for the 3.9L engine
* Upper Intake Manifold Sight Shield Replacement for the 5.3L engine
2. Remove the air cleaner outlet duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
3. Remove the transaxle shift cable from lever and bracket from the transaxle. 4. Disconnect the
transaxle wiring harness connector and disconnect the harness retainer from side cover stud. 5.
Remove the engine mount struts. Refer to the following:
* Engine Mount Strut Replacement for the 3.5L engine
* Engine Mount Strut Replacement for the 3.9L engine
* Engine Mount Strut Replacement for the 5.3L engine
6. Remove the top case side cover bolt (56, 58). 7. Install the engine support fixture to support the
engine/transaxle assembly. Refer to the following:
* Engine Support Fixture for the 3.5L engine
* Engine Support Fixture for the 3.9L engine
* Engine Support Fixture for the 5.3L engine
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13664
9. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) .
10. Remove the left front fender liner. Refer to Front Fender Liner Replacement . 11. Remove the
wheel speed sensor harness from 4 retainers on the lower control arm. 12. Remove the
transmission mount-to-frame nuts. Refer to Transmission Mount Replacement - Left Side (See:
Transmission Mount/Service and
Repair/Transmission Mount Replacement - Left Side) .
13. Remove both stabilizer links and reposition stabilizer to access steering gear- to-frame bolts.
Refer to Stabilizer Shaft Link Replacement (See:
Steering and Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front
Suspension) .
14. Remove steering gear-to-frame bolts and support steering gear. Refer to Steering Gear
Replacement (See: Steering and
Suspension/Steering/Steering Gear/Service and Repair) .
15. Remove the front splash shield. 16. Remove the positive battery cable center retainer at front
frame rail. 17. Remove the left side ball joint and support the left frame rail with a jack stand. 18.
Remove ONLY the left two frame-to-body bolts. DO NOT LOOSEN right side frame-to-body bolts.
Refer to Frame Replacement . 19. Lower frame with a jackstand and remove jackstand. 20.
Position the drain pan under the transaxle. 21. Remove the left drive axle from the transaxle. Refer
to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair) .
22. Secure the drive axle to the strut assembly. 23. Lower the vehicle. 24. Using the engine support
fixture lower the engine assembly to access the transaxle case side cover. 25. Raise the vehicle.
26. Remove the transaxle mount bracket bolts and the bracket from the transaxle.
27. Remove the remaining case side cover bolts (56, 57, 58).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13665
28. Remove the case side cover (53). 29. Remove the case side cover gasket (54). 30. Remove
the case side cover O-ring (59). 31. Clean the side cover gasket mating surfaces.
Installation Procedure
1. Install the J 36850 to the case side cover O-ring (59). 2. Install the O-ring (59) to the case side
cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53), by first installing
any 2 of the upper case side cover bolts (56, 58).
Notice: Refer to Fastener Notice .
5. Install the case side cover bolts (56, 57, 58).
Tighten bolts to 25 N.m (18 lb ft).
6. Install the transaxle mount bracket 7. Install the transaxle mount bracket bolts.
Tighten the bolts to 95 N.m (70 lb ft)
8. Install a jackstand under the left frame rail and raise frame while aligning transaxle mount bolts
with frame and ball joint with steering knuckle. 9. Install and tighten left side frame-to-body bolts.
Refer to Frame Replacement .
10. Install the drive axle to the transaxle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13666
11. Remove the drain pan from under the transaxle. 12. Install transaxle mount nuts. Refer to
Transmission Mount Replacement - Left Side (See: Transmission Mount/Service and
Repair/Transmission
Mount Replacement - Left Side) .
13. Install the ball joint nut and cotter pin. 14. Install steering gear-to-frame bolts. Refer to Steering
Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair
).
15. Install the positive battery cable center retainer on the front frame rail. 16. reposition stabilizer
bar and install both stabilizer links. Refer to Stabilizer Shaft Link Replacement (See: Steering and
Suspension/Suspension/Stabilizer Bar/Stabilizer Link/Service and Repair/Front Suspension) .
17. Install the front splash shield. 18. Install the wheel speed sensor harness to 4 retainers on the
lower control arm. 19. Install the left front fender liner. Refer to Front Fender Liner Replacement .
20. Install the left front wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 21. Lower the vehicle. 22. Remove the
engine support fixture.
23. Install the top case side cover bolt.
Tighten bolts to 25 N.m (18 lb ft).
24. Install the shift cable to the shift lever and transaxle shift cable bracket bolts to shift cable
bracket.
Tighten bolts to 30 N.m (22 lb ft).
25. Connect the transaxle wiring harness connector, and harness retainer to side cover stud. 26.
Install the engine mount struts. Refer to the following:
* Engine Mount Strut Replacement for the 3.5L engine
* Engine Mount Strut Replacement for the 3.9L engine
* Engine Mount Strut Replacement for the 5.3L engine
27. Install the air induction duct. Refer to the following:
* Air Cleaner Outlet Duct Replacement for the 3.5L engine
* Air Cleaner Outlet Duct Replacement for the 3.9L engine
* Air Cleaner Resonator Outlet Duct Replacement for the 5.3L engine
28. Install the engine site shield. Refer to the following:
* Intake Manifold Cover Replacement for the 3.5L engine
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13667
* Intake Manifold Cover Replacement for the 3.9L engine
* Upper Intake Manifold Sight Shield Replacement for the 5.3L engine
Notice: Do not overfill the transmission. Overfilling will result in foaming, loss of fluid, and possible
damage to the transmission.
29. Check and fill the transaxle as necessary. 30. Inspect for fluid leaks.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13668
Valve Body: Service and Repair Control Valve Body Replacement
Control Valve Body Replacement
Tools Required
J 36850 Transjel Lubricant
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Control
Valve Body Cover Replacement) . 2. Remove the oil pump. Refer to Oil Pump Replacement (See:
Fluid Pump/Service and Repair) .
3. Remove the valve body bolts (374-381, 384).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13669
4. Remove the valve body (300) while keeping the spacer plate and gasket assembly (396) with the
transaxle.
5. Remove the ball check valves (372 and 373) from the valve body.
6. Remove the spacer plate and gasket assembly (396) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13670
7. Remove the ball check valves (372) from the case cover.
8. Inspect each check valve seat in the spacer plate (370) for excessive peening. Place a ball
check valve (372) on each seat and use a flashlight in
order to look for visible light between the valve and the seat.
Installation Procedure
Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using
greases other than the recommended assembly lube changes the transaxle fluid characteristics.
Using greases other than the recommended assembly lube causes undesirable shift conditions
and/or filter clogging. Use TRANSJEL(TM) J 36850 or equivalent during the assembly of this unit.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13671
1. Install the ball check valves (372) into the case cover. Use the J 36850 to retain the ball check
valves in their proper locations.
2. Install the gasket and spacer plate assembly (396).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13672
3. Install the ball check valves (372 and 373) into the valve body. Use the J 36850 to retain the ball
check valves in their proper locations.
Important: Do NOT use impact type tools on the valve body or on the oil pump.
4. Install the spacer plate/gasket assembly (396) and the valve body (300).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 13673
Notice: Refer to Fastener Notice .
5. Install the valve body bolts (374-381, 384).
* Tighten the M6 X 1.0 X 20 bolt (381) to 8 N.m (70 lb in).
* Tighten the M6 X 1.0 X 30 bolt (376) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 45 bolt (377) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 55 bolt (378) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 60 bolt (375) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 65 bolt (374) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 85 bolt (384) to 12 N.m (106 lb in).
* Tighten the M6 X 1.0 X 95 bolt (379) to 16 N.m (11 lb ft).
* Tighten the M8 X 1.25 X 90 bolt (380) to 25 N.m (18 lb ft).
6. Install the oil pump. Refer to Oil Pump Replacement (See: Fluid Pump/Service and Repair) . 7.
Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Control Valve
Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-007B > Jun > 09
> A/T - Key Cannot Be Removed/No Shift From Park
Wiring Harness: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-007B > Jun > 09
> A/T - Key Cannot Be Removed/No Shift From Park > Page 13682
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-007B
> Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park
Wiring Harness: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-007B
> Jun > 09 > A/T - Key Cannot Be Removed/No Shift From Park > Page 13688
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Page 13689
Wiring Harness: Service and Repair
Wiring Harness Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve (315A,
315B, 322, 334 and/or 440), TFP manual valve
position switch (395) and the temperature sensor (391).
3. Remove the wiring harness (224).
Installation Procedure
1. Install the wiring harness (224).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Page 13690
2. Install the wiring harness to the solenoid valve (315A, 315B, 322, 334 and/or 440), TFP manual
valve position switch (395) and the temperature
sensor (391).
3. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Valve
Body/Service and Repair/Control Valve Body Cover
Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information
Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information
INFORMATION
Bulletin No.: 07-07-30-010B
Date: June 19, 2009
Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using
TIS Software
Models:
2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models)
2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section
and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section
07 - Transmission/Transaxle).
Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles
when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool
platform and software will be required for use with all GM Global Architecture (Global A) vehicles
beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet
Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R)
communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number
09-00-89-019 (Introduction of New Global Diagnostic System (GDS)).
This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and
upload it to a computer. The procedure is written for an automatic transmission data snapshot on a
Saturn AURA, but is similar for all applications. This procedure is written with the assumption the
user has a basic understanding of how to use a Tech 2(R) already.
Capturing a Snapshot of the Vehicle Data Stream
1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi
module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen.
3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the
scan tool's display. Bolded selections are vehicle specific.
- Select "2007"
- Select "Passenger Car (F0)"
- Select "Saturn"
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13695
- Select "Z"
- Select "Aura"
- Select "Powertrain"
- Select "3.6L LY7"
- Select "Transmission"
- Select "Transmission Data"
5. From the application menu, select F3: Snapshot.
- Choose trigger type and trigger point, as described above.
- It is preferred to trigger on "Any Code" (F1)
- If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on
the next screen.
- Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the
events before and after the code sets.
6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going
to record for live viewing.
- When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1
and F5) are selected.
- If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key
to actually record data. Otherwise, it will automatically start recording when a DTC is set.
- Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1
minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is
selected).
Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third
snapshot is requested, the first snapshot will be overwritten.
7. When the snap shot data has been recorded, exit to the Main Menu, then power down and
disconnect the Tech 2(R) from the vehicle.
Uploading and Sending a Snapshot via TIS2WEB
Figure 8
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13696
Figure 9
1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a
arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen
just like the TIS 2000 procedure described above.
Figure 10
3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure
10. Make sure the Tech 2(R) is connected to the
computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech
2(R) should start blinking and a line will start scrolling across the screen indicating it is
communicating with your computer.
Figure 11
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13697
4. Once communication is established and you select the file you want to upload, you will see a
screen similar to below. You can email the file
directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail"
as shown in Figure 11.
Figure 12
5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill
in the information as requested and then click
send. Include the VIN in the subject line.
6. After all the information is entered, hit the send button. After sending the file, you will receive a
confirmation box letting you know the e-mail was
sent successfully.
7. It is recommended to now save the file to your computer using the same procedure as if you
were using TIS 2000 in case your recipient doesn't
receive your email with the snapshot data.
Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is
no way to access your sent mail in TIS2WEB like a regular e-mail program.
Sending a Snapshot to GM TAC
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13698
During your call with GM TAC on a current case, you may be advised to send a copy of the Tech
2(R) or VDR Snapshot Data to the TAC e-mail box.
U.S. Dealers - send to e-mail box
[email protected]
Canadian Dealers - send to e-mail box
[email protected]
Please complete the following:
- Be sure to review the procedures listed above for uploading and sending a Snapshot via
TIS2WEB.
- If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink
Website in the articles (December 2002, December 2003, July 2004 and January 2006).
- Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of
the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The
email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email
can not be processed and will be deleted.
Please send only REQUESTED Snapshot Data to the TAC e-mail box.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13699
Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine
Crankcase and Subsystems Flushing Info.
INFORMATION
Bulletin No.: 04-06-01-029E
Date: April 29, 2010
Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM
Simplified Maintenance Schedule to Enhance Customer Service Experience
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and add information about the
proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D
(Section 06 - Engine/Propulsion System).
An Overview of Proper Vehicle Service
General Motors is aware that some companies are marketing tools and equipment to support a
subsystem flushing procedures. These dedicated machines are in addition to many engine oil,
cooling system, fuel system, A/C, transmission flush and steering system additives available to the
consumer. GM Vehicles under normal usage do not require any additional procedures or additives
beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified
Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are
designed to aid and accelerate the process of fluid changing with these flushing machines.
Engine Crankcase Flushing
General Motors Corporation does not endorse or recommend engine crankcase flushing for any of
its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing
indicate incompatibility with GM engine components and the potential for damage to some engine
seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT
COVERED under the terms of the New Vehicle Warranty.
GM Authorized Service Information: Detailed, Descriptive, and Complete
If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service
Document containing a procedure and, if required, provide, make available, or require the specific
use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is
fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has
recognized the need for fuel injector cleaning methods on some engines, though under normal
circumstances, this service is not part of the maintenance requirements.
GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to
be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning
of the fuel injectors with preventative maintenance suggestions to maintain optimum performance.
You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional
information on this subject.
Subsystem Flushing
Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized
practices to be performed after catastrophic failures or extreme corrosion when encountered in
radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006.
This practice is NOT required or recommended for normal service operations.
The use of external transmission fluid exchange or flush machines is NOT recommended for the
automatic or manual transmission. Use of external machines to replace the fluid may affect the
operation or durability of the transmission. Transmission fluid should only be replaced by draining
and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter
Replacement.
Approved Transmission Flushing Tool (Transmission Cooler Only)
The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM
vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096.
Service Is Important to You and Your Customer
General Motors takes great pride in offering our dealerships and customers high quality vehicles
that require extremely low maintenance over the life of the vehicle. This low cost of ownership
builds repeat sales and offers our customers measurable economy of operation against competing
vehicles.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 13700
Providing responsible services at the proper intervals will greatly aid your dealership with repeat
business, and additional services when required. Most customers appreciate and gain trust in the
dealership that informs and offers them just what they need for continued trouble-free operation.
Examine your service department's practices and verify that all Service Consultants and
Technicians focus on customer satisfaction, vehicle inspections, and other products at time of
service. Use this opportunity to upgrade the services you provide to your customers. Here are a
few suggestions:
- Take the time required to align your dealership service practices with the new GM Simplified
Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to
create a "mirror image" in your advertising and dealer service pricing that is easily understandable
to your customer. Taking advantage of this new service strategy may greatly increase your
dealership service sales and customer retention while decreasing the frequency of visits and
inconvenience to your customer.
- Review your program to ensure that all vehicles coming in are evaluated for safety and wear
items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp
functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service
Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is
illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and
what the required repair would cost. In addition to the possibility of increased emissions and
driveability concerns, many customers are unaware that lower gas mileage may also result, with
additional cost to the customer.
- Be complete in your service recommendations. Some sales opportunities are not being fully
pursued nationally. Focus on overlooked but required maintenance that has real benefits to the
customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond
replacement time, they may impede airflow decreasing A/C and heating performance. Make sure
these filters are part of your recommended service. Note that some of our vehicles may not have
been factory equipped but will accept the filters as an accessory.
- Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I
and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's
world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic
car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax
to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase
customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source
of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved
resale value of a completely maintained vehicle.
- For customers who clean and maintain the appearance of their vehicles themselves encourage
the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax
Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of
many customers who try it just once. If your dealership give samples of these products with new
car purchases, customers may already be sold on the product but not willing to make a special trip
to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with
these products and consider instituting compensation programs for Service Consultants who
suggest these products. Many consumers faced with an intimidating wall full of car care products
sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM
that they know will not harm the finish of their vehicle. We suggest these competitively priced basic
vehicle care products to emphasize:
In USA:
- #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L)
- #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g)
- #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L)
- #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L)
- #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L)
In Canada:
- #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL
- #992727 GM Glass Cleaner Aerosol 500 g
- #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL
- #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL
- #10953202 GM Vehicle Care Wheel Brite 473 mL
- #88901678 GM Vehicle Care Odor Eliminator 473 mL
- Display signboards with the installed price for popular GM Accessories such as running boards
and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a
service visit.
- Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit
Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer
with more reasons to identify your dealership as the best place to go for parts and service.
Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and
provide value to your customer. Many businesses exist profitably as an oil change location, a
vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and
provide these services with the inherent trust of your customer, under the GM Mark of Excellence.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 11-03-08-001 > Apr
> 11 > Steering - Growl Type Noise Coming from Front of Vehicle
Axle Shaft: Customer Interest Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 11-03-08-001 > Apr
> 11 > Steering - Growl Type Noise Coming from Front of Vehicle > Page 13711
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: >
11-03-08-001 > Apr > 11 > Steering - Growl Type Noise Coming from Front of Vehicle
Axle Shaft: All Technical Service Bulletins Steering - Growl Type Noise Coming from Front of
Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: >
11-03-08-001 > Apr > 11 > Steering - Growl Type Noise Coming from Front of Vehicle > Page 13717
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Testing and Inspection
Constant Velocity Joint: Testing and Inspection
Wheel Drive Shaft Outer Joint Inspection
Special Tools
J 8059 Snap Ring Pliers
Disassembly Procedure
1. Remove the outer constant velocity (CV) joint and boot from the wheel drive shaft. Refer to
Wheel Drive Shaft Replacement (See: Service and
Repair) .
2. Remove any grease from the CV joint.
3. Using the J 8059 , remove the retaining ring (3) from the wheel drive shaft (4).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Testing and Inspection > Page 13721
4. Install the outer CV joint assembly in a vise.
Important: The following procedure will have to be repeated until all the ball bearing are removed
form the cage.
5. Using a brass drift (1), gentle tap the cage until the ball bearing can be removed from the cage.
6. Using a small screwdriver, remove the ball bearings from the CV joint. 7. Position the cage and
the inner race so they are level.
8. Remove the ball bearings from the CV joint in sequence.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Testing and Inspection > Page 13722
Important: Position the cage so that the larger radius corners of the cage windows are facing up.
9. Position the cage at a 90° to the centerline of the outer race.
10. Align the cage windows with the lands of the outer race. 11. Lift and remove the cage and the
inner race from the outer race.
12. Position the cage and the inner race so that the larger radius corners of the cage windows are
up. 13. Rotate the inner race 90° to the center line of the cage. 14. Align the lands of the inner race
with the windows of the cage. 15. Move the inner race land into the cage window. 16. Rotate the
inner race down and remove it from the cage. 17. Clean the following items thoroughly with the
proper cleaning solvent:
* The inner race
* The outer race
* The cage
* The ball bearings
* The exposed end of the wheel drive shaft
Important: The internal parts of the CV joint are NOT SERVICED separately. The outer CV joint is
serviced as an assembly.
18. If any of the above items are found to have excessive wear or are damaged, replace the outer
CV joint as an assembly.
Assembly Procedure
1. Position the cage so that the larger radius corners of the cage windows are up. 2. Position the
inner race 90° to the centerline of the cage. 3. Insert the inner race through the bottom of the cage.
4. Align the lands of the inner race with the windows of the cage. 5. Move the inner race land into
the cage window. 6. Rotate the inner race down and remove it from the cage. 7. Rotate the inner
race within the cage so that the grooved surface of the inner race is facing up. 8. Align the inner
race ball bearing tracks with the cage windows.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Testing and Inspection > Page 13723
9. Wrap a clean shop towel around the CV joint outer race splined shaft.
10. Place the outer race vertically in a bench vise. 11. Position the cage and the inner race at a 90°
to the centerline of the outer race. 12. With the inner race and the cage assembly in a vertical
position, insert the cage and the inner race into the outer race.
Important: The larger radius corners of the cage windows should be positioned up and the grooved
surface of the inner race should be visible.
13. Position the cage and the inner race so that they are level in the vise. 14. Rotate the
appropriate component (s), and align the cage windows and the inner race ball bearing tracks with
the outer race ball bearing tracks. 15. Position a cage window and the inner race ball bearing track
for the ball bearing installation.
Important: When performing the following procedure, the opposing cage window and the inner ball
bearing track will be accessible for the ball bearing installation.
16. Press down on the cage following one of the outer race ball bearing tracks. 17. Install the ball
bearing through the cage window onto the inner race ball bearing track.
Important: The following service procedure will have to be performed after each ball bearing has
been installed.
18. After the first ball bearing has been installed, use a brass drift and a hammer and gently tap the
cage in order to drive the cage and the inner race
down completely in the outer race.
Important: After the ball bearing has been installed, there should be NO GAP between the ball
bearing and the inner race.
19. Position the cage and the inner race so that they are level. 20. Using a plastic hammer, lightly
tap the ball bearing into place.
21. Install the ball bearings in sequence. 22. Repeat steps 18 thru 20 until all the ball bearings are
installed. 23. Install the outer CV joint and boot on the wheel drive shaft. Refer to Wheel Drive
Shaft Replacement (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
* J 8059 Snap Ring Pliers (Parallel Jaw)
* J 35910 Drive Axle Seal Clamp Pliers
* J 41048 Drive Axle Swage Ring Clamp
Removal Procedure
Notice: Do not cut through the wheel drive shaft inboard boot during service. Cutting through the
boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing
surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.
1. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring,
taking care not to damage the halfshaft bar. 2. Remove the large seal retaining clamp (2) from the
tripot joint with side cutters. Discard the large seal retaining clamp. 3. Separate the inboard seal
from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along
the halfshaft bar.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13726
5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13727
6. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059 , and
tripot boot (4). Discard the boot and rings. 7. Clean the halfshaft bar (5). Use a wire brush in order
to remove any rust in the boot mounting area (grooves). 8. Inspect the needle rollers, needle
bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage.
Replace any
damaged parts with the appropriate kit.
Installation Procedure
1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1)
and the small swage ring (2) onto the halfshaft
bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13728
3. Mount J 41048 in a vise and proceed as follows:
1. Position the inboard end (1) of the halfshaft assembly in tool J 41048 . 2. Align the top of seal
neck on the bottom die using the indicator. 3. Place the top half of the J 41048 on the lower half . 4.
Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could
cause damage to the halfshaft inboard seal. 5. Insert the bolts (2). 6. Tighten the bolts by hand until
snug.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13729
Notice: Refer to Fastener Notice .
4. Align the following items:
* The halfshaft inboard seal (1)
* The halfshaft bar
* The swage ring (2)
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between
each bolt until both sides are bottomed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13730
5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13731
6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the
spacer ring (2) into the groove of the halfshaft bar J 8059 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13732
8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the
remainder of the grease to repack the housing.
Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).
9. Install the new trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the
housing (1) over the tripot joint spider assembly on the halfshaft bar.
12. Slide the large diameter of the halfshaft inboard seal (2), with the larger clamp (3) in place, over
the outside of the trilobal tripot bushing and
locate the lip of the seal in the groove.
13. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the
trilobal tripot bushing in order to equalize the
pressure. Remove the tool.
14. Position the joint assembly at the proper vehicle dimension.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13733
* For 4.6L V8 engines, dimension a = 107 mm (4.21 in).
* For 4.0L V6 engines, dimension a = 111 mm (4.37 in).
* For 3.8L supercharged V6 engines, dimension a = 111 mm (4.37 in).
* For all others, dimension a = 95 mm (3.75 in).
15. Align the following items while latching:
* The halfshaft inboard seal
* The tripot housing (2)
* The large seal retaining clamp (3)
Crimp the seal retaining clamp with J 35910 to 176 N.m (130 lb ft). Add the breaker bar (5) and the
torque wrench (4) to J 35910 if necessary.
16. Check the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue
tightening until gap dimension of 2.60 mm (0.102
in) is reached.
17. Fully stroke the joint several times to disperse the grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13734
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Tools Required
* J 35910 Drive Axle Seal Clamp Pliers
* CH-48894 Wheel Drive Shaft Boot Clamp Pliers
Removal Procedure
Important: The following service procedure is to be performed after the wheel drive shaft has been
removed from the vehicle.
1. Clamp the drive axle shaft in a soft jawed vice.
Notice: Do not cut through the wheel drive shaft inboard boot during service. Cutting through the
boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing
surface may lead to water and dirt intrusion and premature wear of the constant velocity
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13735
joint.
2. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and
the boot (3). 3. Using a pair of side cutters, remove the boot clamp (4) from the boot (3) and the
wheel drive shaft (5). 4. Discard the boot clamps (2) and (4). Use NEW clamps only.
5. Using a block of wood and a hammer, remove the CV joint from the wheel drive shaft.
6. Remove the boot (1) from the wheel drive shaft (2). 7. Inspect the outer CV joint for damage and
wear. Refer to Wheel Drive Shaft Outer Joint Inspection (See: Testing and Inspection) .
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13736
1. Position the boot (1) on the wheel drive shaft (2).
2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).
3. Place approximately half the grease from the service kit inside the outboard boot and pack the
CV joint with the remaining grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13737
4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft.
5. Install the boot clamp (4) on the boot (3) and the wheel drive shaft (5). 6. Install the boot clamp
(2) on the boot (3) and the CV joint housing (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13738
Important: Ensure that the boot clamp is properly positioned around the entire circumference of the
boot.
7. Using the , crimp the boot clamp. 8. Measure the clamp end gap dimension. The gap should not
exceed 2.15 mm (0.85 in).
The gap should not exceed 2.15 mm (0.85 in).
9. Using the CH-48894 , close the boot clamp. Ensure the boot clamp is securely closed and
seated properly on the boot.
10. Remove the wheel drive shaft from the bench vise. 11. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion four to five times. 12. Install the wheel drive shaft
assembly. Refer to Wheel Drive Shaft Replacement (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot
Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
* J 8059 Snap Ring Pliers (Parallel Jaw)
* J 35910 Drive Axle Seal Clamp Pliers
* J 41048 Drive Axle Swage Ring Clamp
Removal Procedure
Notice: Do not cut through the wheel drive shaft inboard boot during service. Cutting through the
boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing
surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.
1. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring,
taking care not to damage the halfshaft bar. 2. Remove the large seal retaining clamp (2) from the
tripot joint with side cutters. Discard the large seal retaining clamp. 3. Separate the inboard seal
from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along
the halfshaft bar.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13743
5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13744
6. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059 , and
tripot boot (4). Discard the boot and rings. 7. Clean the halfshaft bar (5). Use a wire brush in order
to remove any rust in the boot mounting area (grooves). 8. Inspect the needle rollers, needle
bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage.
Replace any
damaged parts with the appropriate kit.
Installation Procedure
1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1)
and the small swage ring (2) onto the halfshaft
bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13745
3. Mount J 41048 in a vise and proceed as follows:
1. Position the inboard end (1) of the halfshaft assembly in tool J 41048 . 2. Align the top of seal
neck on the bottom die using the indicator. 3. Place the top half of the J 41048 on the lower half . 4.
Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could
cause damage to the halfshaft inboard seal. 5. Insert the bolts (2). 6. Tighten the bolts by hand until
snug.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13746
Notice: Refer to Fastener Notice .
4. Align the following items:
* The halfshaft inboard seal (1)
* The halfshaft bar
* The swage ring (2)
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between
each bolt until both sides are bottomed.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13747
5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13748
6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the
spacer ring (2) into the groove of the halfshaft bar J 8059 .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13749
8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the
remainder of the grease to repack the housing.
Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).
9. Install the new trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the
housing (1) over the tripot joint spider assembly on the halfshaft bar.
12. Slide the large diameter of the halfshaft inboard seal (2), with the larger clamp (3) in place, over
the outside of the trilobal tripot bushing and
locate the lip of the seal in the groove.
13. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the
trilobal tripot bushing in order to equalize the
pressure. Remove the tool.
14. Position the joint assembly at the proper vehicle dimension.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13750
* For 4.6L V8 engines, dimension a = 107 mm (4.21 in).
* For 4.0L V6 engines, dimension a = 111 mm (4.37 in).
* For 3.8L supercharged V6 engines, dimension a = 111 mm (4.37 in).
* For all others, dimension a = 95 mm (3.75 in).
15. Align the following items while latching:
* The halfshaft inboard seal
* The tripot housing (2)
* The large seal retaining clamp (3)
Crimp the seal retaining clamp with J 35910 to 176 N.m (130 lb ft). Add the breaker bar (5) and the
torque wrench (4) to J 35910 if necessary.
16. Check the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue
tightening until gap dimension of 2.60 mm (0.102
in) is reached.
17. Fully stroke the joint several times to disperse the grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13751
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot
Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Tools Required
* J 35910 Drive Axle Seal Clamp Pliers
* CH-48894 Wheel Drive Shaft Boot Clamp Pliers
Removal Procedure
Important: The following service procedure is to be performed after the wheel drive shaft has been
removed from the vehicle.
1. Clamp the drive axle shaft in a soft jawed vice.
Notice: Do not cut through the wheel drive shaft inboard boot during service. Cutting through the
boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing
surface may lead to water and dirt intrusion and premature wear of the constant velocity
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13752
joint.
2. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and
the boot (3). 3. Using a pair of side cutters, remove the boot clamp (4) from the boot (3) and the
wheel drive shaft (5). 4. Discard the boot clamps (2) and (4). Use NEW clamps only.
5. Using a block of wood and a hammer, remove the CV joint from the wheel drive shaft.
6. Remove the boot (1) from the wheel drive shaft (2). 7. Inspect the outer CV joint for damage and
wear. Refer to Wheel Drive Shaft Outer Joint Inspection (See: Constant Velocity Joint/Testing and
Inspection) .
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13753
1. Position the boot (1) on the wheel drive shaft (2).
2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).
3. Place approximately half the grease from the service kit inside the outboard boot and pack the
CV joint with the remaining grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13754
4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft.
5. Install the boot clamp (4) on the boot (3) and the wheel drive shaft (5). 6. Install the boot clamp
(2) on the boot (3) and the CV joint housing (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 13755
Important: Ensure that the boot clamp is properly positioned around the entire circumference of the
boot.
7. Using the , crimp the boot clamp. 8. Measure the clamp end gap dimension. The gap should not
exceed 2.15 mm (0.85 in).
The gap should not exceed 2.15 mm (0.85 in).
9. Using the CH-48894 , close the boot clamp. Ensure the boot clamp is securely closed and
seated properly on the boot.
10. Remove the wheel drive shaft from the bench vise. 11. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion four to five times. 12. Install the wheel drive shaft
assembly. Refer to Wheel Drive Shaft Replacement (See: Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B >
May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
13769
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-07-30-009B Date: 080501
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 08-07-30-009B Date: 080501
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
13770
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 08-07-30-009B Date: 080501
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
13771
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Tools Required
J 42129 Wheel Hub Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair) .
3. Disconnect the wheel speed sensor electrical connector (2), if equipped.
4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. 5. Remove
the front wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft
Assembly/Service and Repair) . 6. Remove the brake rotor. Refer to Front Brake Rotor
Replacement .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 13777
7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in
order to push the wheel drive shaft out of the wheel bearing/hub.
9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub.
Important: Ensure that the wheel drive shaft outer seal/boot is not damaged.
10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for
re-installation.
Installation Procedure
1. Install the wheel bearing/hub with the splash shield as noted during removal.
Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are
removed. Failure to replace these fasteners after they become loose or are removed may cause
loss of vehicle control and personal injury.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 13778
Notice: Refer to Fastener Notice .
2. Install NEW wheel bearing/hub bolts.
Tighten the NEW wheel bearing/hub bolts to 130 N.m (96 lb ft).
3. Install the brake rotor and caliper. Refer to Front Brake Rotor Replacement . 4. Install the front
wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service
and Repair) .
Important: Ensure that the connector clip engages the bracket properly.
5. Install the wheel speed sensor electrical connector to the bracket, if equipped.
6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair) . 8. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 13779
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Removal Procedure
Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is
non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing
assembly.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair) . 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement .
Rear Wheel Speed Sensors
4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove
the park brake cable from the park brake actuator. Refer to Parking Brake Rear Cable
Replacement (Z7U) . 6. Remove the mounting bolts from the rear bearing/hub.
7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park
brake actuator from the rear wheel bearing/hub. Refer to Parking Brake Actuator Replacement .
Installation Procedure
1. Install the park brake actuator to the rear wheel bearing/hub. Refer to Parking Brake Actuator
Replacement . 2. Install the wheel bearing/hub and park brake assembly to the knuckle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 13780
Notice: Refer to Fastener Notice .
3. Install the wheel bearing/hub-to-knuckle bolts.
Tighten the bolts to 75 N.m (55 lb ft).
4. Install the park brake cable to the park brake actuator. Refer to Parking Brake Rear Cable
Replacement (Z7U) .
Rear Wheel Speed Sensors
5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the
brake rotor. Refer to Rear Brake Rotor Replacement . 7. Install the tires and wheels. Refer to Tire
and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 8.
Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 11-03-08-001 > Apr > 11 >
Steering - Growl Type Noise Coming from Front of Vehicle
Axle Nut: Customer Interest Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 11-03-08-001 > Apr > 11 >
Steering - Growl Type Noise Coming from Front of Vehicle > Page 13790
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 11-03-08-001 > Apr >
11 > Steering - Growl Type Noise Coming from Front of Vehicle
Axle Nut: All Technical Service Bulletins Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 11-03-08-001 > Apr >
11 > Steering - Growl Type Noise Coming from Front of Vehicle > Page 13796
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > Page 13797
Axle Nut: Specifications
Front Wheel drive shaft nut. Tighten the nut to ...................................................................................
................................................................................................ 160 N.m (118 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flex Plate Bolts - First Pass ................................................................................................................
........................................................ 20 N.m (15 lb ft) Flex Plate Bolts - Second Pass .......................
............................................................................................................................................. 50 N.m
(37 lb ft) Flex Plate Bolts - Final Pass .................................................................................................
..................................................................... 100 N.m (74 lb ft)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
13801
Flex Plate: Service and Repair
Engine Flywheel Replacement
Removal Procedure
1. Remove the automatic transmission. Refer to Transmission Replacement (RPOs LZE/LZ9)
Transmission Replacement (RPO LS4) . 2. Remove the flywheel bolts and flywheel. 3. Clean and
inspect the engine flywheel. Refer to Engine Flywheel Cleaning and Inspection (See: Engine,
Cooling and Exhaust/Engine/Service and
Repair/Overhaul) .
Installation Procedure
Important: The flywheel does not use a locating pin for alignment and will not initially seat against
the crankshaft flange or spacer if applicable, but will be pulled onto the crankshaft by the engine
flywheel bolts. This procedure requires a 3-stage tightening process.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
13802
1. Install the flywheel to the crankshaft. 2. Apply threadlock to the threads of the flywheel bolts.
Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and
Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) .
Notice: Refer to Fastener Notice .
3. Install the engine flywheel bolts.
* Tighten the bolts a first pass in sequence to 20 N.m (15 lb ft).
* Tighten the bolts a second pass in sequence to 50 N.m (37 lb ft).
* Tighten the bolts a final pass in sequence to 100 N.m (74 lb ft).
4. Install the automatic transmission. Refer to Transmission Replacement (RPOs LZE/LZ9)
Transmission Replacement (RPO LS4) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics
Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating
Characteristics
INFORMATION
Bulletin No.: 03-07-29-004G
Date: December 15, 2010
Subject: Manual Transmission Operating Characteristics
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior
Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission
Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation
information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle).
Important Even though this bulletin attempts to cover operating characteristics of manual
transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar
vehicle and if possible, with similar mileage. Even though many of the conditions are described as
characteristics and may not be durability issues, GM may attempt to improve specific issues for
customer satisfaction.
The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that
repair attempts will not change. The following are explanations and examples of conditions that will
generally occur in all manual transmissions. All noises will vary between transmissions due to build
variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and
clutch, level of insulation, etc.
Basic Information
Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a
sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced
with clutch damper springs and dual mass flywheels. However, some speed variation will make it
through to the transmission. This can create noise as the various gears will accel and decel against
each other because of required clearances.
Cold Operation
Manual transmission operation will be affected by temperature because the transmission fluid will
be thicker when cold. The thicker fluid will increase the amount of force needed to shift the
transmission when cold. The likelihood of gear clash will also increase due to the greater time
needed for the synchronizer assembly to perform its function. Therefore when the transmission is
cold, or before it has reached operating temperature, quick, hard shifts should be avoided to
prevent damage to the transmission.
Gear Rattle
Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a
combustion knock type of noise) type noises usually occur while operating the engine at low RPMs
(lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or
while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low
engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with
the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles
without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However,
dual-mass flywheels do not eliminate all noise.
Neutral Rattle
There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to
the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles
with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with
the clutch engaged, the sudden stop of the engine will create a rapid change in angular
acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the
components, this will create a noise. This type of noise should not be heard if the clutch is released
(pedal pushed to the floor).
Backlash
Backlash noise is created when changing engine or driveline loading. This can occur when
accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and
unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle
loading, etc. and is created from the necessary clearance between all of the mating gears in the
transmission, axle(s) and transfer case (if equipped).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 13807
Shift Effort
Shift effort will vary among different style transmissions and synchronizer designs. Usually the
more heavy duty the transmission, the higher the shift effort because of the increased mass of the
components. Shift effort can also be higher in cold weather because the fluid will be thicker.
Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift
effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder
will only increase the chance of rushing past the synchronizer leading to grinding while shifting.
Non-Synchronized Gears
Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various
transmissions, along with all gears in some medium duty transmissions, may be non-synchronized.
This means there is not a mechanism to match input and output shaft speeds to allow for a smooth
shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is
attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind.
The grinding can be reduced by coming to a complete stop and pausing for a moment before
shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty
non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft
(driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other
methods. If the driver is not able to perform this function properly, there will be gear grinding with
each improperly completed shift. Driver training may be required to correct this condition. Clutch
brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a
stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a
stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the
floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle
stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The
clutch brake is intended to only be used while at a stop. Care must be taken to not activate the
clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or
missed shift.
Skip Shift
Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models
may follow) equipped with the 6-speed manual transmission have a feature referred to as a
"skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is
illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel
economy standards. The conditions for this feature are: engine coolant at normal operating
temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to
Service Information or the Owner Manual for more details.)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Powertrain Component Views > Page
13814
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 13815
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 13816
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 13817
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E Automatic Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > 4T65-E Automatic Transaxle > Page 13824
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13825
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13826
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 13827
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > 4T65-E - Automatic
Transaxle > Page 13832
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 13833
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E Automatic Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > 4T65-E Automatic Transaxle > Page 13838
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 13839
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 13840
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle > Page 13846
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page
13847
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and
Repair > Fluid Temperature Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and
Repair > Fluid Temperature Sensor Replacement > Page 13850
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and
Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and
Repair > Fluid Temperature Sensor Replacement > Page 13851
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair) . 8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 13858
Pressure Regulating Solenoid: Service and Repair
Pressure Control Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the pressure control solenoid (PCS) electrical connector. 3. Remove the PCS
retaining clip (314E).
4. Remove the PCS (322).
Installation Procedure
1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical
connector. 4. Install the case side cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot
Be Removed/No Shift From Park
Shift Interlock Solenoid: Customer Interest A/T - Key Cannot Be Removed/No Shift From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T - Key Cannot
Be Removed/No Shift From Park > Page 13867
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T Key Cannot Be Removed/No Shift From Park
Shift Interlock Solenoid: All Technical Service Bulletins A/T - Key Cannot Be Removed/No Shift
From Park
ENGINEERING INFORMATION
Bulletin No.: 08-07-30-007B
Date: June 08, 2009
Subject: EI08045 - Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter
Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI)
Solenoid Harness)
Models:
2007-2009 Chevrolet Impala
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for information from the field and provide repair information. Please discard
Corporate Bulletin Number 08-07-30-007A (Section 07 - Transmission/Transaxle).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on either of the following conditions:
- The key cannot be removed from the ignition.
- The transmission gear selector (shifter) cannot be moved out of the PARK position.
Cause
This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI)
solenoid harness which can make it difficult to install. In some instances, the wiring looms are
tangled, causing stress on the wires in the connector at the BTSI. If the BTSI harness is routed
incorrectly, it may also result in a wire pinching issue.
Correction
Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to
the BTSI.
Inspection/Routing and Repair of the BTSI Wiring Harness/Connector
1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2.
For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped
wires. Refer to SI for repair procedures.
BTSI Wiring Harness Incorrectly Routed
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 08-07-30-007B > Jun > 09 > A/T Key Cannot Be Removed/No Shift From Park > Page 13873
3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above
show the BTSI harness routed incorrectly.
BTSI Wiring Harness Routed Correctly
4. Reroute the wiring to create available slack and avoid future occurrences.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Technical Service Bulletins > Page 13874
Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Notice: To prevent component damage, DO NOT use metal tools to remove the trim.
Important: Use only a plastic trim tool to lift the shift lever bezel or trim plate. Do not use any tool
between the shift lever bezel or trim plate and the shifter.
2. Remove the center console. Refer to Front Floor Console Replacement (Impala) . 3. Disconnect
the automatic transaxle shift lock actuator electrical connector (1). 4. Remove both ends of the
automatic transaxle shift lock actuator from the pivot points.
Installation Procedure
1. Install both ends of the automatic transaxle shift lock actuator to the pivot points. 2. Connect the
automatic transaxle shift lock actuator electrical connector (1). 3. Install the center console. Refer
to Front Floor Console Replacement (Impala) . 4. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection (RPO LS4) Battery Negative Cable
Disconnection and Connection (RPOs LZE/LZ4/LZ8) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle
Shift Solenoid: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle > Page 13880
Shift Solenoid: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
In the Center Console - Floor Shifter
In the Center Console - Floor Shifter
1 - Floor Shifter 2 - A/T Shift Lock Control Solenoid
Steering Column Components - Column Shift
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
4T65-E - Automatic Transaxle > Page 13881
Lower Steering Column Components
1 - Automatic Transmission Shift Lock Control Solenoid 2 - Steering Column
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13884
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13885
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13886
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13887
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13888
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13889
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13890
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13891
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13892
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13893
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13894
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13895
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13896
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13897
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13898
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13899
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13900
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13901
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13902
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13903
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 13904
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Diagram Information and Instructions > Page 13999
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Diagram Information and Instructions > Page 14000
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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Diagram Information and Instructions > Page 14001
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 14002
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 14003
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Diagram Information and Instructions > Page 14004
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagram Information and Instructions > Page 14006
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagram Information and Instructions > Page 14008
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 14011
Shift Solenoid: Connector Views
Component Connector End Views
1-2 Shift Solenoid (1-2 SS) Valve
2-3 Shift Solenoid (2-3 SS) Valve
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Repair > 1-2 Shift Solenoid Valve Replacement
Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement
1-2 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining
clip (314D)
4. Remove the 1-2 shift solenoid (315A).
Installation Procedure
1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3.
Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
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Repair > 1-2 Shift Solenoid Valve Replacement > Page 14015
Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining
clip (314C).
4. Remove the 2-3 shift solenoid (315B) and the O-ring (316).
Installation Procedure
1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining
clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover.
Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve
Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the
ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be
affected as new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
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Information > Locations
Torque Converter Clutch Solenoid: Locations
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 14104
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information > Diagrams > Diagram Information and Instructions > Page 14145
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 14146
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 14147
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Solenoid
Replacement
Torque Converter Clutch Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Remove the TCC
solenoid retaining clip (314) 4. Remove the TCC solenoid (315).
Installation Procedure
1. Install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the
TCC solenoid electrical connector. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 14150
Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width
Modulation Solenoid Replacement
Torque Converter Clutch Pulse Width Modulation Solenoid Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect and reposition the electrical connectors from the following:
* If equipped internal mode switch
* 2-3 Shift solenoid valve assembly (315B)
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
3. Remove the oil pump bolts (230, 231).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 14151
4. Remove the oil pump (200) from the valve body (300).
5. Disconnect the torque converter clutch pulse width modulation (TCC PWM) solenoid electrical
connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM
solenoid (334).
Installation Procedure
1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3.
Connect the TCC PWM solenoid electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 14152
4. Install the oil pump (200) to the valve body (300).
Notice: Refer to Fastener Notice .
5. Install the oil pump body and cover bolts (230, 230).
* Tighten the nine bolts (231) to 12 N.m (106 lb in).
* Tighten the two bolts (230) to 16 N.m (12 lb ft).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service and Repair > Torque Converter Clutch Solenoid Replacement > Page 14153
6. Reposition and connect the electrical connectors to the following:
* Automatic transaxle fluid pressure manual valve position switch assembly (395)
* 2-3 Shift solenoid valve assembly (315B)
* If equipped internal mode switch
7. Install the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Powertrain Component Views
Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Powertrain Component Views > Page 14160
Control Module: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 14161
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Page 14162
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Page 14163
Control Module: Service and Repair
Transmission Control Module Replacement
Transmission Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Fluid Pressure Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 14170
Fluid Pressure Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Locations > Page 14171
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Locations > Page 14172
Fluid Pressure Sensor/Switch: Service and Repair
Transmission Fluid Pressure Manual Valve Position Switch Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve
position switch to the control valve body (300).
Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
4. Carefully remove the fluid pressure manual valve position switch (395). 5. Inspect the fluid
pressure manual valve position switch (395) for the following conditions:
* Damaged electrical connector terminals
* Damaged seals
* Damaged switch membranes
* Debris on the switch membranes
Installation Procedure
Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual
valve position switch is very delicate.
1. Carefully install the fluid pressure manual valve position switch (395).
Notice: Refer to Fastener Notice .
2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve
body (300).
* Tighten the control valve body bolt (375) to 12 N.m (106 lb in).
* Tighten the control valve body bolt (379) to 16 N.m (12 lb ft).
* Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness. 4. Install the case side cover. Refer to Control Valve Body
Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations > Page 14173
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
5. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Transmission Mode Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 14178
Transmission Mode Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > Page 14179
Transmission Mode Switch: Diagrams
Component Connector End Views
Automatic Transmission Internal Mode Switch (IMS)
Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle
Transmission Speed Sensor: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > 4T65-E - Automatic Transaxle > Page 14184
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 14185
Transmission Speed Sensor: Diagrams
Component Connector End Views
Automatic Transmission Input Shaft Speed (AT ISS) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Locations > Page 14186
Transmission Speed Sensor: Service and Repair
Input Speed Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector.
3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440).
5. Inspect the input speed sensor (440) for the following conditions:
* Damaged or missing magnet
* Damaged housing
* Bent or missing electrical terminals
* Damaged speed sensor clip (441)
Installation Procedure
1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3.
Connect the input speed sensor electrical connector. 4. Install the case side cover. Refer to Control
Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > 4T65-E - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations 4T65-E - Automatic Transaxle
Automatic Transmission Electronic Component Views
Internal Electronic Component Locations
Internal Electronic Component Location
10 - Vehicle Speed Sensor (VSS) Assembly 315a - 1-2, 3-4 Shift Solenoid (SS) Valve Assembly
315b - 2-3 Shift Solenoid (SS) Valve Assembly 322 - Pressure Control (PC) Solenoid Valve
Assembly 334 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve
Assembly 391 - Transmission Fluid Temperature (TFT) Sensor 395 - Transmission Fluid Pressure
(TFP) Manual Valve Position Switch Assembly 440 - Automatic Transmission Input Shaft Speed
(A/T ISS) Sensor Assembly 811 - Lever Assembly-Manual Shaft Detent with Shift Position Switch Internal Mode Switch (IMS)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > 4T65-E - Automatic Transaxle > Page 14192
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Transaxle
1 - Pressure Control (PC) Solenoid Valve 2 - 1-2 Shift Solenoid (SS) Valve 3 - Automatic
Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve 5 - Automatic
Transmission Internal Mode Switch (IMS) 6 - Vehicle Speed Sensor (VSS) 7 - Automatic
Transmission Fluid Pressure Manual Valve Position Switch 8 - Automatic Transmission Fluid
Temperature Sensor 9 - Torque Converter Clutch (TCC) Solenoid Valve
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > Page 14193
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement
Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor
Replacement
Fluid Temperature Sensor Replacement
Removal Procedure
1. Remove the case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
2. Disconnect the wiring harness assembly from the fluid temperature sensor (391). 3. Remove the
fluid temperature sensor (391).
Installation Procedure
1. Install the fluid temperature sensor (391).
2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the
case side cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve Body/Service and
Repair/Control Valve Body Cover Replacement) .
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
4. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement > Page 14196
Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement
Thermo Element Replacement
Tools Required
J 34094-A Thermo Element Height Gage
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil pan.
Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and
Repair) .
3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element
(121) and the thermo element plate (122).
Installation Procedure
1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate
(122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and
the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin
(120) and the washer.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Service and Repair > Fluid Temperature Sensor Replacement > Page 14197
6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121)
must contact the thermo element plate (122). 7. Install the oil pan. Refer to Oil Pan Replacement
(See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair) . 8. Lower the vehicle.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The
ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as
new TAP values are learned.
9. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic
Transmission/Transaxle/Description and
Operation/Transmission Adaptive Functions) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 14203
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: Customer Interest ABS/TCS - Stabiltrak Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Stabiltrak
Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Powertrain Component Views
Electronic Brake Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Powertrain Component Views > Page 14219
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 14220
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM) (without JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 14221
Electronic Brake Control Module (EBCM) (JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 14222
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Locations > Page 14223
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Replacement
Brake Pressure Modulator Valve Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement > Page 14228
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement > Page 14229
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Bracket Replacement
Brake Pressure Modulator Valve Bracket Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Service and Repair
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: Customer Interest ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052
Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 14241
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - ABS/TCS Lamps ON/DTC's
C0035-C0052 Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 14247
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 14248
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Right Rear Wheel Speed Sensor (Left Similar)
1 - Wheel Speed Sensor (WSS) - Right Rear (Wheel Speed Sensor (WSS) - Left Rear Similar)
Right Front Wheel Speed Sensor (Left Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 14249
1 - Wheel Speed Sensor (WSS) Connector - Right Front (Wheel Speed Sensor (WSS) Connector Left Front Similar) 2 - Wheel Speed Sensor (WSS) - Right Front (Wheel Speed Sensor (WSS) Left Front Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 14250
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor (WSS) - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Left Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 14251
Wheel Speed Sensor (WSS) - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Right Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 14252
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures
Yaw Rate Sensor: Procedures
Yaw Rate Reference Table Resetting
Circuit Description
Optimum vehicle stability enhancement system (VSES) function is dependant on many variables.
The characteristics of a specific vehicle, that affect vehicle handling or input signals to the
electronic brake control module (EBCM), ultimately determine how the VSES operates. The basic
EBCM software must be fine tuned as the vehicle is operated. This logic is referred to as adaptive
learning.
Adaptive learning is accomplished by maintaining a yaw rate sensor/lateral accelerometer data
table in the EBCM memory. As the vehicle is operated, the table is populated with data that is later
referenced, and sometimes modified, to allow the EBCM to provide the best possible stability
control for the specific vehicle.
Important: If the data in the yaw rate sensor/lateral accelerometer data table becomes unreliable,
false activations of the VSES, poor VSES performance or false setting of DTC C0186 or C0196
may result.
A replacement EBCM may have some unreliable data stored in the yaw rate sensor/lateral
accelerometer data table. For this reason, it is important to perform the yaw rate reference table
reset procedure after replacing the EBCM.
Replacement of the yaw rate sensor/lateral accelerometer or the installation of different size tires
may also the data stored in the table to become unreliable. Therefore, the yaw rate reference table
reset procedure must be performed.
This procedure is to be used only for vehicles equipped with VSES (JL4).
1. Turn OFF the ignition. 2. Disconnect the yaw rate sensor/lateral accelerometer harness
connector. 3. Start the engine. 4. Apply firm and steady pressure to the brake pedal for at least 10
seconds. 5. Turn OFF the ignition. 6. Reconnect the yaw rate sensor/lateral accelerometer harness
connector. 7. Turn ON the ignition and use the scan tool to clear the DTCs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures > Page 14257
Yaw Rate Sensor: Removal and Replacement
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Service and Repair > Procedures > Page 14258
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important:
* Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
* The automated bleed procedure must be performed when a new brake pressure modulator valve
(BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake
fluid.
* The automated bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out away from the brake modulator assembly, which is then forced out at the
brake corners by the pressure bleeder.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic
System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or
replace components as needed.
4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) .
6. Inspect the battery state of charge. Refer to Battery Inspection/Test . 7. Install a scan tool. 8.
Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps:
1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select
Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed
10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Important: *
Apply the brake pedal when instructed, using moderate effort.
* Ensure the pedal remains applied until instructed to release by the scan tool.
* Do not exceed the time period allowed by the scan tool for having the bleeder valves open.
* The bleed sequence for each corner is as follows:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14263
- Left front
- Right front
Right rear
- Left rear
11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated
bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble
Code (DTC) List - Vehicle to
diagnose the DTC.
13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect
for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15.
Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal
and Installation . 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder
Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling) .
19. Road test the vehicle while confirming the brake pedal remains high and firm.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14264
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
Important: If you have performed a brake master cylinder bench bleeding, disconnected the brake
pipes from the master cylinder, replaced the ABS pressure modulator valve, or disconnected the
jumper lines from the master cylinder to the ABS pressure valve, you MUST use the pressure
bleeding procedure to remove all the air from the system. Refer to Hydraulic Brake System
Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) (See: ) .
3. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian
P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains
at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
4. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 5.
Install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the
bleeder valve, then have the assistant slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air
has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left front hydraulic circuit, install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
18. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
19. Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
Important: If it is determined that air was induced into the system upstream of the ABS modulator
prior to servicing, the Antilock Brake System Automated Bleed Procedure (See: ) must be
performed.
20. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still
feels spongy after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
21. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14265
22. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 35589-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, replaced the ABS
pressure modulator valve, or disconnected the
brake lines between master cylinder and ABS on this vehicle, you must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11(R) GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
If removal of the reservoir cap is necessary, clean the outside of the reservoir on and around the
cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port, and rotate the line at the master cylinder at
least 30 degrees, so that the line will be
positioned BELOW the MAX fill line on the brake master cylinder reservoir. Tighten the line nut
securely.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7.
Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds,
then repeat steps 3.5-3.7 until all air is purged from the same port of the master cylinder. 9. With
the front brake pipe installed securely to the master cylinder - after all air has been purged from the
front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.5-3.7,
ensuring that the line is rotated below the master cylinder MAX fill line.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened, and that they remain in their new rotated positions below the MAX fill line of the brake
fluid reservoir.
4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J
29532 , or equivalent. Add Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to
approximately the half-full point.
7. Connect the J 29532 , or equivalent, to the J 35589-A . 8. Charge the J 29532 , or equivalent, air
tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow
pressurized brake fluid to enter the brake system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R) GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
14. Repeat steps 11-13 for the LEFT FRONT wheel hydraulic circuit bleeder valve. 15. Loosen the
bleeder valve to purge air from the wheel hydraulic circuit. It is important that both bleeder valves
be open at the same time. Allow
fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve.
16. With the right rear and left front wheel hydraulic circuit bleeder valve tightened securely - after
all air has been purged from the right rear and left
front hydraulic circuit - install a proper box-end wrench onto the LEFT REAR and RIGHT FRONT
wheel hydraulic circuit bleeder valve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14266
17. Install a transparent hose over the end of the bleeder valve, then repeat step 15. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Loosen the rear master cylinder jumper line nut slightly (just enough to rotate the line), and
rotate the rear master cylinder hydraulic pipe back to
the original position, and tighten the line nut.
20. Reposition the front master cylinder jumper line to the original position in a similar manner to
step 19. 21. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or
equivalent, from the J 35589-A . 22. Remove the J 35589-A from the brake master cylinder
reservoir. 23. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme
11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
24. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 25. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .
2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure
(See: ) .
26. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
27. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14267
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Overhaul (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Overhaul) or Master Cylinder Replacement (See: Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also
perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or
equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks
and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See:
Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master
Cylinder Reservoir Replacement) . Replace the brake master cylinder reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and
Repair/Overhaul/Front Brake Caliper Overhaul) or Front Brake Caliper Replacement (See: Disc
Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper
Replacement)
* Rear Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and
Repair/Overhaul/Rear Brake Caliper Overhaul) or Rear Brake Caliper Replacement (See: Disc
Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 14268
Replacement)
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canada P/N 992667) or
equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair
Brake Pedal Assy: Service and Repair
Brake Pedal Assembly Replacement
Removal Procedure
1. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side . 2. Push the body control module (BCM) up and move the bottom of the
BCM away from and out of the mounting bracket slot. Position the BCM
aside.
3. Disconnect the brake pedal position sensor electrical connector. 4. Release the wiring harness
clips from the bracket.
5. Remove the brake pedal pushrod retaining clip from the brake pedal. 6. Remove the brake pedal
pushrod and washer from the brake pedal.
7. Remove the brake pedal nut and bolt. 8. Remove the brake pedal and bushings.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 14272
1. Install the brake pedal and bushings.
Notice: Refer to Fastener Notice .
2. Install the brake pedal nut and bolt.
Tighten the brake pedal nut and bolt to 40 N.m (30 lb ft).
3. Install the brake pedal washer and pushrod to the brake pedal. 4. Install the brake pedal pushrod
retaining clip to the brake pedal. 5. Secure the wiring harness clips to the bracket. 6. Connect the
brake pedal position sensor electrical connector. 7. Insert the top of the BCM up into the mounting
bracket, then engage the bottom of the BCM into the mounting bracket slot. 8. Install the left
closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information
Brake Caliper: Technician Safety Information
Caliper Piston Removing Caution
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information > Page 14278
Brake Caliper: Vehicle Damage Warnings
Brake Caliper Notice
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Page 14279
Brake Caliper: Testing and Inspection
Brake Caliper Inspection
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores:
The movement of the caliper pistons into the caliper bores should be smooth and even. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement
Brake Caliper: Removal and Replacement
Front Brake Caliper Replacement
Front Brake Caliper Replacement
Rear Brake Caliper Replacement
Rear Brake Caliper Replacement
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14282
Caution: Refer to Brake Dust Caution . Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway
between the maximum-full point and the minimum allowable level, then no brake fluid needs to be
removed from
the reservoir before proceeding. If the brake fluid level is higher than midway between the
maximum-full point and the minimum allowable level, then remove brake fluid to the midway point
before proceeding.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 4. Remove the
rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation . 5. Hand
tighten 2 wheel lug nuts to retain the rotor to the hub.
6. Install a large C-clamp (3) over the top of the brake caliper (2) and against the back of the
outboard brake pad. 7. Tighten the C-clamp (3) until the caliper piston is pushed into the caliper
bore enough to slide the caliper off the rotor. 8. Remove the C-clamp (3) from the caliper.
9. Remove the brake hose-to-caliper bolt (1) from the caliper.
Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper
and/or the brake hose end.
10. Plug the opening in the rear brake hose (2) to prevent excessive brake fluid loss and
contamination.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14283
11. Remove the caliper bolts (1 and 3). 12. Remove the caliper (3) from the rotor (4) and the caliper
bracket (1). 13. Inspect the caliper bracket bolt boots on the caliper bracket for the following
conditions:
* Cuts
* Tears
* Deterioration Replace any damaged caliper bracket bolt boots. Refer to Rear Disc Brake
Hardware Replacement (See: Service and Repair/Rear Disc Brake Hardware Replacement) .
14. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new caliper
bolts, including bushings, when installing caliper.
Installation Procedure
1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are
in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14284
2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads. 3.
Lubricate the 2 bolt boots (13 and 4) in the caliper bracket (12). Use silicone grease.
Notice: Refer to Fastener Notice .
4. Install the caliper bolts (1 and 3). Ensure that the bolt boots fit securely in the groove of the
caliper bolts. Be sure not to pinch or tear the boots. If
the boots are damaged, they must be replaced.
Tighten the bolts to 44 N.m (32 lb ft).
Important: Install NEW copper gaskets.
5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose
(2). 6. Install the brake hose-to-caliper bolt to the brake caliper.
Tighten the bolt to 54 N.m (40 lb ft).
7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the rear tire and the wheel
assembly. Refer to Tire and Wheel Removal and Installation . 9. Lower the vehicle.
10. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder
Reservoir Filling (See: Hydraulic System/Brake
Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) .
11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake
Bleeding/Service and Repair)Hydraulic Brake System
Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
12. Inspect the hydraulic brake system for brake fluid leaks.
Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement
Removal Procedure Caution: Refer to Brake Dust Caution .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14285
may cause damage to the brake hose and in turn may cause a brake fluid leak.
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics
wire or equivalent. It is not necessary to disconnect
the hydraulic brake flexible hose from the caliper. Refer to Front Brake Caliper Replacement (See:
Front Brake Caliper Replacement) .
2. Remove the front brake pads.
3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1).
Installation Procedure
Important: To ensure that the proper clamp load will be present when installed. It is imperative that
the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of
all debris and inspected before proceeding with installation.
1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the
knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488) or equivalent,
to the threads of the brake caliper bracket bolts (2).
Notice: Refer to Fastener Notice .
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten the caliper bracket bolts to 180 N.m (133 lb ft).
4. Install the front brake pads. 5. Install the caliper. Refer to Front Brake Caliper Replacement
(See: Front Brake Caliper Replacement) .
Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement
Removal Procedure Caution: Refer to Brake Dust Caution .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics
wire or equivalent. It is not necessary to disconnect
the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (See:
Rear Brake Caliper Replacement) .
2. Remove the rear brake pads.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14286
3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1).
Installation Procedure
Important: To ensure that the proper clamp load will be present when installed. It is imperative that
the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of
all debris and inspected before proceeding with installation.
1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the
knuckle. 2. Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the
threads of the brake caliper bracket bolts (2).
Notice: Refer to Fastener Notice .
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten the caliper bracket bolts to 120 N.m (88 lb ft).
4. Install the rear brake pads. 5. Install the caliper. Refer to Rear Brake Caliper Replacement (See:
Rear Brake Caliper Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14287
Brake Caliper: Overhaul
Front Brake Caliper Overhaul
Front Brake Caliper Overhaul
Tools Required
* J 8092 Driver Handle 3/4 inch-10
* J 45863 Dust Seal Installer
Caution: Refer to Brake Fluid Irritant Caution .
Disassembly Procedure
1. Drain all the brake fluid from the caliper.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while
applying compressed air. This could result in serious injury.
Important: In the following service procedure, the caliper piston may become damage when it is
removed from the brake caliper assembly. If this happens, DO NOT reuse the piston. Discard and
replaced with new.
2. Install the brake caliper in a suitable holding devise. 3. Insert a piece of wood in the brake
caliper. 4. Cover the brake caliper with a shop towel. 5. Using compressed filtered, non-lubricated
air, apply the air to the remove the pistons from the brake caliper.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14288
6. If one of the pistons fails to be removed from the brake caliper, perform the following steps.
1. Reposition the piston that has been removed back in the brake caliper. 2. Using a small block of
wood and a C-clamp, slowly tighten the C-clamp until the piston it is half way in the brake caliper. It
does not have to
be fully seated.
3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover
the brake caliper with a shop towel. 5. Using compress filtered, non lubricated air, apply the air to
the remove the pistons from the brake caliper.
7. Remove the pistons (3) from the caliper bores. 8. Remove the piston seals (2) from the caliper
bores. Do not use a metal tool. 9. Remove the bleeder valve cap (5).
10. Remove the bleeder valve (6) from the caliper housing (1). 11. Clean the bleeder valve, the
caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow
out the brake fluid
passages. Use dry and filtered compressed air.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14289
12. Remove the boots from the caliper bores. Do not scratch the caliper bores. 13. Replace the
pistons or the caliper if any of the following conditions exist:
* Scoring in the caliper bores
* Corrosion in the caliper bores
* Pitting in the caliper bores
* Damage to the pistons (phenolic)
14. Clean the brake caliper assembly with denatured alcohol. 15. Dry with filtered , lubricated
compressed air.
Assembly Procedure
Important: When applying the clean brake fluid to the piston bores and pistons, only apply the
brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons
DO NOT become contaminated with dirt or other foreign material.
1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14290
2. Install the piston seal in the brake caliper.
3. Install the dust seal on the piston.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14291
Important: Position the piston in the bore so that it is straight and level.
4. Install the piston in the brake caliper.
5. Position a piece of wood across the piston to be installed. 6. Applying equal pressure by hand
while pushing down, install the piston in the bore. 7. Remove the piece of wood.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14292
8. Using the J 8092 (1) and the J 45863 (2) , install the piston dust seal in the brake caliper.
Notice: Refer to Fastener Notice .
9. Install the bleeder valve in the brake caliper housing.
Tighten the bleeder valve to 13 N.m (115 lb in).
10. Install bleeder valve cap.
Rear Brake Caliper Overhaul
Rear Brake Caliper Overhaul
Removal Procedure Caution: Refer to Brake Dust Caution .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14293
Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Remove the rear brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough
air to ease the pistons out of the bores. If the pistons are blown out, even with the padding
provided, it may be damaged.
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air
into the caliper bore through the fluid inlet hole.
3. Remove the retaining ring that secures the dust boot to the caliper housing.
4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot
seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore .
Discard the piston seal.
Important: Do not use abrasives to clean the brake caliper piston.
6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured
alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with
non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust,
and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt
to remove the imperfection with a fine emery paper. If the imperfection
cannot be removed, replace the caliper assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14294
10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper
bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or
damage to the chrome plating. Replace the caliper piston if any of these conditions exist.
Installation Procedure
1. Lubricate the new piston seal (4) with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Delco
Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from
a clean, sealed
brake fluid container onto the outer surface area of the caliper piston (3).
4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust
boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the
caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore.
8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Install the bleeder
valve and cap to the caliper and tighten the valve securely.
10. Install the rear brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
* Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of
the mounting plates.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 14298
Brake Pad: Testing and Inspection
Brake Pad Inspection
* Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are
removed from the vehicle.
* If replacement is necessary, always replace disc brake pads in axle sets.
* Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally
occurs at the trailing edge of the disc brake pads.
* Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn
prematurely. The disc brake pad wear should be approximately even per axle set.
* Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake
pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor
(2). The wear indicator will then produce an audible, high-pitched warning noise during wheel
rotation.
* Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of
the mounting plates.
* Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake
pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure
the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the
length of the disc brake pads, replace the disc brake pads.
* Verify that any disc brake pad shims that may be required are in place and not damaged or
excessively corroded. Replace any missing or damaged shims in order to preserve proper disc
brake performance.
* Replace the disc brake pads if any have separated from the mounting plates.
* Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause
noise or otherwise impair disc brake performance.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement
Brake Pad: Service and Repair Front Disc Brake Pads Replacement
Front Disc Brake Pads Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 14301
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 14302
Brake Pad: Service and Repair Rear Disc Brake Pads Replacement
Rear Disc Brake Pads Replacement
Removal Procedure Caution: Refer to Brake Dust Caution .
1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway
between the maximum-full point and the minimum allowable level, then no brake fluid needs to be
removed from
the reservoir before proceeding. If the brake fluid level is higher than midway between the
maximum-full point and the minimum allowable level, then remove brake fluid to the midway point
before proceeding.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 4. Remove the
rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation . 5. Install a
hand tightened lug nut to retain the rotor to the hub.
6. Compress the caliper piston enough for clearance. Use a C-clamp (3).
7. Remove the upper caliper bolt (2).
Notice: Use care to avoid damaging pin boot when rotating caliper.
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 14303
8. Pivot the caliper down in order to access the pads. It is not necessary to remove the caliper.
9. Remove the brake pads (2) from the caliper bracket.
10. Remove the 2 pad clips (1) from the caliper bracket. 11. Inspect the caliper mounting hardware
for the following conditions:
* Cuts
* Tears
* Deterioration Replace any hardware if damage exists. Refer to Rear Disc Brake Mounting and
Hardware Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Disc
Brake Mounting and Hardware Inspection - Rear) .
12. Inspect the caliper dust boot for the following conditions:
* Cuts
* Tears
* Deterioration Replace the caliper dust boot if damage exists. Refer to Brake Caliper Inspection
(See: Brake Caliper/Testing and Inspection) .
13. Inspect the caliper bolts for corrosion or damage. If corrosion exists, use new caliper bolts
when installing the caliper.
Installation Procedure
1. Bottom the piston into the caliper bore.
Use a C-clamp before installing new brake pads in order to compress the piston. Use an old brake
pad or wooden block across the face of the piston to avoid damage to the piston or the caliper
boot.
2. Install the 2 retainers (1) to the caliper bracket.
Important: The wear sensor is on the outside pad. The sensor is positioned at the trailing or
downward edge of the pad during forward wheel rotation.
3. Install the pads (2) to the caliper bracket.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 14304
Notice: Use care to avoid damaging pin boot when rotating caliper.
4. Swing the caliper (3) upward in position around the pads. 5. Lubricate the bolt and the bolt boot.
Use silicone grease.
Notice: Refer to Fastener Notice .
6. Install the upper caliper bolt (2).
Tighten the caliper bolt to 44 N.m (32 lb ft).
7. Remove the wheel lug nut retaining the rotor to the hub. 8. Install the rear tire and the wheel
assembly. Refer to Tire and Wheel Removal and Installation . Align the previous marks on the
wheel, hub and
bearing.
9. Lower the vehicle.
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11
until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake
pads. 13. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder
Reservoir Filling (See: Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) .
14. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad and
Rotor Burnishing) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 14305
Brake Pad: Service and Repair Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing Caution: Refer to Road Test Caution .
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures
Technical Service Bulletin # 00-05-22-002L Date: 090326
Brakes- Disc Brake Warranty Service And Procedures
INFORMATION
Bulletin No.: 00-05-22-002L
Date: March 26, 2009
Subject: Disc Brake Warranty Service and Procedures
Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2
2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X
(Canada Only) 1999-2010 Saturn Vehicles (Canada Only)
EXCLUDING 2009-2010 Chevrolet Corvette ZR1
Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake
corner and wheel design, assembly plant build processes and dealership required tools like the
On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing
base brake service. Due to this change, you are no longer required to enter the LRO measurement
on the repair order or in the warranty system failure code section. The bulletin information below
and the base brake labor operations have been updated accordingly. Due to this change it is more
important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration
Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes).
For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service
Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional
information, the Service Technical College lists a complete index of available Brake courses. This
information can be accessed at www.gmtraining.com > resources > training materials > brakes
courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake
Certification program 15003.16H.
Important
PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR
NEXT GM BRAKE SERVICE.
The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a
successful brake service.
1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace
2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel
3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness
(REQUIRED on Repair Order)
Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly
calibrated.
4. Properly reassemble the brake corner using proper torque tools, torque specification and torque
sequence - wheel lug nuts.
* The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after
refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec
after refinish and not the discard spec.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14310
Bulletin Format
***REPAIR ORDER REQUIRED DOCUMENTATION
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14311
Important
When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake
Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor
Thickness are required and MUST be written/documented on the repair order, or for your
convenience, complete the form (GM Brake Service Repair Order Documentation for Required
Measurements) shown above and attach it to the repair order. If the Warranty Parts Center
generates a request, this Documentation/Form must be attached to the repair order that is sent
back.
Important
Documentation of brake lathe maintenance and calibration as recommended by the lathe
manufacturer must be available for review upon request.
Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED
When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before
refinish) and REFINISHED thickness (measured thickness after refinish) MUST be
written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is
necessary, only the original thickness measurement needs to be recorded.
Repair Order Documentation - Explanation of Part Replacement - REQUIRED
If replacement of a brake component is necessary, proper documentation on the repair order is
required. See the following examples:
^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a
prior brake service. After rotor measurement, it was determined that refinishing the rotor again
would take it under the Minimum Thickness specification.
^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads
contaminated by fluid leak at caliper.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14312
TOOL INFORMATION
CORRECTION PLATE PART INFORMATION
Refer to TSB 01-05-23-001 for the Brake Align(R) application chart.
For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be
submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are
available through the following suppliers:
- Dealer Equipment and Services
- Brake Align(R) LLC (U.S. Dealers Only)
* We believe this source and their products to be reliable. There may be additional manufacturers
of such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items, which may be available from
other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14313
WARRANTY INFORMATION
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14314
WORKSHEET - BRAKE LATHE CALIBRATION
Important
Brake lathe calibration should be performed and recorded monthly or if you are consistently
measuring high LRO after rotor refinishing.
Disclaimer
GM Brake Service Procedure
GM BRAKE SERVICE PROCEDURE
1. Remove the wheel and caliper.
2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following
steps:
Important
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14315
If performing routine Brake Service for worn pads only, and the rotors are not damaged and
measure within specification - DO NOT REFINISH ROTORS.
1. Remove the rotor(s).
2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points
should be taken and the lowest measurement
should be recorded.
3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for
Minimum Thickness specification/other. In
most cases, the rotor should be refinished unless the measurement taken makes it obvious that
refinishing the rotor would take the measurement under the Minimum Thickness specification (then
replacement is necessary). DO NOT use any other manufacturers rotor specifications.
3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as
noted in the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz
Wheel(R).
If rotors are not to be refinished - Go To Step 8.
Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris
(which includes removal of Hubless rotors) is critical and MUST be performed whether using an
On-Car or Bench Lathe Refinish Procedure.
5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are
using.
Important Only replace the rotors if they do not meet the Minimum Thickness specification.
Important DO NOT REFINISH NEW ROTORS.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with
the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut.
Bench Type Lathe
1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of
debris or burrs. For more information, see the
"Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin.
3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools
into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a
full turn
4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
7. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
On-Car Type Lathe
1. Reinstall the rotor(s).
Important
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14316
When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is
critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe.
Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating
driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep
their body out of the wheel well area until the machine has reached its normal operating RPM.
2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
Important When raising the vehicle on the lift, be sure to have it at a good working height (waist
high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the
lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming
out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time
of the lathe.
3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the
vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb
ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the
adapter.
Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor
retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface.
4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for
run-out in the hub.
5. Once the computer indicates the compensation process was successful, on the outboard area of
the rotor, position the cutting tools one eighth
of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the
rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters
to the zero setting plus just enough to clean up the entire rotor surface.
9. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit
sandpaper to obtain a non-directional finish.
10. Dismount the lathe, but leave the lathe adapter attached to the vehicle.
6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish
washing soap) or wipe it clean with GM approved
brake cleaner, P/N 88862650 (Canadian P/N 88901247).
Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as
a by-product of machining to the pad material during the seating process, thus reducing the
opportunity for squeaks or other noises to occur.
7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer
to the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
8. Setting up to measure for Lateral Run Out (LRO):
Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these
steps are being left in the overall procedure as a good check to be performed in the case of a
repeat pulsation complaint. If you are not checking for LRO, go to step 16.
Bench-Type Lathe
1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean
and free of debris.
2. Mount the new, original or refinished rotor onto the vehicle hub.
Important Always hold the rotor on the bottom half so any debris that may be dislodged from the
vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor
falling over on the studs can release rust from the vents on the rotor.
3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto
the studs.
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14317
4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical
washers (with the tapered hole side facing
out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it.
5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start
and snug the lug nuts by hand.
6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with
the lug nut opposite of the one you first
tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not
completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the
lug nuts in a star pattern to the specific vehicle torque specification.
7. DO NOT reinstall the caliper or the wheel at this time.
On-Car Type Lathe
1. Leave the On-Car adapter on the wheel.
2. Proceed to Step 9.
9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor
outboard friction surface approximately 6.35 mm
(0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of
the rotor.
Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false
readings.
10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification
(0.050 mm (0.002 in) or LESS).
1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is
indicated and set the dial indicator to zero.
2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading
(rotor "high spot"). Note the amount and mark
the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location.
If the high point falls between two studs, mark both studs. In instances where the vehicle has
"capped lug nuts" you should mark the hub.
11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is
necessary. Go to Step 15 if this is the first rotor
completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050
mm (0.002 in), go to Step 12.
12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to
correct for LRO:
Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of
the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of
LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure").
Hubless Rotor
1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B),
choose the correct plate to bring the rotor
LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006
in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the
instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B.
2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high
spot") or between the two points marked (if
the "high spot" is between two wheel studs).
Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer
to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO.
Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates
together on one hub. NEVER attempt to reuse a previously installed Correction Plate.
3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8.
Make sure to index the rotor correctly to the
marks made in step 10, otherwise LRO will be comprised.
Hubbed / Captured / Trapped Rotor
1. Measure the rotor thickness.
2. Refinish or replace the rotor (see Service Information for further details).
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14318
13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification.
14. If using,
BENCH LATHE - DO NOT remove conical washers and lug nuts at this time.
ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain
rotor position.
Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the
hub and install the top conical washer and lug nut first to ensure no debris falls between the
surface while removing the adapter. Then, install the remaining conical washers and lug nuts.
Otherwise, LRO will be comprised.
15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO).
16. Reinstall the rotors on both sides of the vehicle and perform the following steps:
1. Reinstall the calipers and pads.
2. Pump the brakes to pressurize the calipers.
3. Remove the lug nuts/conical washers.
4. Install and properly torque the wheels.
Important It is critical to follow the star pattern wheel torque procedure and use the proper tools
(torque stick or torque wrench) as referenced in SI.
17. Road test the vehicle to verify the repairs.
Brake Lathe Calibration Procedure
BRAKE LATHE CALIBRATION PROCEDURE
Calibration of the brake lathe should be performed and recorded monthly or whenever post-service
brake rotor LRO measurements are consistently reading above specification.
BENCH-TYPE LATHE
Use the following procedure to calibrate a Bench-type brake lathe:
1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it
from rotating, rotate the rotor 180 degrees.
2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as
checking the run out on the vehicle.
3. Rotate the arbor and read the runout.
4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the
rotor.
Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe
(this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an
On-Car type lathe).
Machining the Inside Bell Clamp (Bench Type Lathe Only)
Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to
accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat
against the shoulder surface using slight pressure. When the burrs are gone, clean the surface.
Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with
the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing
the burrs, clean the hub.
Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then
spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool
bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the
face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360
degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and
line up these marks before machining a rotor. A magic marker can be used to make the match
marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell
Clamps used.
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14319
Important
If runout is still present, contact the brake lathe supplier.
ON-CAR TYPE LATHE
Use the following procedure to calibrate an On-Car brake lathe:
1. Connect the lathe to a vehicle using the appropriate adapter.
2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a
flat surface on the cutting head.
3. Turn on the lathe and press the "start" button so the lathe begins to compensate.
4. Once compensation is complete, note the runout as measured by the dial indicator. Measured
runout at this point is overstated given that it is
outside the rotor diameter.
5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor
diameter), calibration must be tightened. Follow
manufacturer's instructions for tightening the calibration of the lathe. This information is found in the
manual supplied with the lathe.
Important If the machine is taking a long time to compensate during normal use, prior to checking
the lathe calibration, it is recommended that the machine be disconnected from the adapter and the
adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will
accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will
change the location of the runout (phase) relative to the machine and thus possibly allow for quick
compensation as a result of the position change.
The following information has been added as a reference to ensure your Pro-Cut PFM lathe
provides a consistent smooth surface finish over long term usage.
Cutting Tips / Depth of Cut / Tip Life
The cutting tips must be right side up. Reference marks always face up. The cutting tips may not
have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will
provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits,
make sure that the seat area for the tip on the tool is free and clear of debris.
Cutting Head
On each brake job, the technician must center the cutting head for that particular vehicle using one
of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the
technician use one hand to push the head firmly and squarely back into the dovetail on the slide
plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do
this could result in chatter occurring during the cut.
Tool Holder Plate (Cutting Head)
The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a
technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts
of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not
cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder
plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head
from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder
plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide
plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting
arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will
show itself by having the back of the cutting arm lifting off the surface of the tool holder.
Gib Adjustment / Loose Gib
As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do
this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment
process, which you should perform when required after monthly checks or whenever surface finish
is inconsistent.
Brake Pulsation
BRAKE PULSATION
Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes
the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The
"pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may
result from two basic conditions:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14320
1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner
assembly is virtually undetectable unless measured
(with a dial indicator after the brake service) and will not be detected as brake pulsation during an
after brake service test drive. If the brake corner is assembled with excessive LRO (greater than
0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles.
Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor
thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in
4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will
develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts).
Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the
cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the
service event for the condition to develop. The customer does not usually make the connection
between the service event and the awareness of the pulsation. The proper usage of torque
wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation
conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly
increases the likelihood of pulsation after wheel service.
The following are examples of pulsation conditions and reimbursement recommendations:
- If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually
got worse, normally the repair would be covered. The customer may tolerate the condition until it
becomes very apparent.
- If a GM dealer performed a prior brake service, consider paying for the repair and then strongly
reinforce proper brake lathe maintenance.
- If the customer had the brake service done outside of a GM dealership, normally GM would not
offer any assistance.
- If a customer indicated they had wheel service, ask who performed the service. Then;
- If a GM dealer performed the service, consider paying for the repair and then strongly reinforce
the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM
products. Each technician needs to use torque sticks properly every time the wheel nuts are
tightened.
- If the customer had the wheel service done outside of a GM dealership, normally GM would not
offer any assistance.
2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another
form of thickness variation, which can cause a
pulsation concern and can be addressed as follows:
- Cosmetic Corrosion:
In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary.
- Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi):
At times more extensive corrosion can cause pulsation due to thickness variation. This usually
happens when the vehicle is parked for long periods of time in humid type conditions and the
braking surface area under the pads corrodes at a different rate compared to the rest of the braking
surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15
moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple
moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure"
below.
- Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi):
In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and
miles can cause the same type of pulsation complaint due to thickness variation. In these cases,
the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against
the darker surface. This darker surface is usually due to build-up, on the rotor material surface,
caused by a combination of corrosion, pad material and heat. To correct this condition, follow the
"Brake Rotor Clean-up Procedure" below.
- Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 +
km (5,000 + miles) :
At times, more extensive corrosion over time and miles can cause pulsation due to thickness
variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by
a combination of corrosion, pad material and heat. When rotor measurements are taken, the low
areas are usually close to the original rotor thickness (new rotor) measurement and the high areas
usually measure more than the original rotor thickness (new rotor) measurement (depending on
mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure"
described below.
Important In some flaking instances, cleaning-up this type of corrosion may require more rotor
material to be removed then desired. Customer consideration should be taken in these situations
and handled on a case by case basis, depending on the amount/percentage of rotor life remaining
and the vehicle's warranty time and miles.
Brake Rotor Clean-Up Procedure
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14321
BRAKE ROTOR CLEAN-UP PROCEDURE
Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and
parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is
clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure"
section in this bulletin.
1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools into the
rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same procedure. If
zero is passed during the process, reset zero.
4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
5. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important In many of these instances, such a minimal amount of material is removed from the rotor
that customer satisfaction is not a concern for future brake services. This procedure is intended to
"Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut",
"refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor
material/life. If the brake lathe equipment being used is not capable of removing minor amounts of
material while holding tolerances, further lathe maintenance, repair, updates or equipment
replacement may be necessary.
Brake Noise
BRAKE NOISE
Some brake noise is normal and differences in loading, type of driving, or driving style can make a
difference in brake wear on the same make and model. Depending on weather conditions, driving
patterns and the local environment, brake noise may become more or less apparent. Verify all
metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and
lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a
"slip-stick" vibration of brake components. While intermittent brake noise may be normal,
performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the
noise persists and is consistently occurring, a brake dampening compound may be applied to the
back of each pad. This allows parts to slide freely and not vibrate when moving relative to each
other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or
equivalent.
The following noises are characteristics of all braking systems and are unavoidable. They may not
indicate improper operation of the brake system.
Squeak/Squeal Noise:
- Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is
applied to the brake pedal.
- Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes
and/or high humidity.
Grinding Noise:
- Common to rear brakes and some front disc brakes during initial stops after the vehicle has been
parked overnight.
- Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few
stops.
Groan Noise:
A groan type noise may be heard when stopping quickly or moving forward slowly from a complete
stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard
braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS
activation.
Key Points - Frequently Asked Questions
KEY POINTS - FREQUENTLY ASKED QUESTIONS
- Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor,
either surface finish or LRO?
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14322
A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the
dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no
difference in the cutting/surface finish and LRO are just the same as with a non-floating axle.
- Q: Which lathe is essential for performing brake work, the bench or on-car?
A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These
lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality
brake service.
- Q: What is the expected tip life for an on-car lathe?
A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When
using the Pro-Cut the cutting depth should be set to take all material needed to get below rust
grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381
mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or
"finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last
between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts.
- Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and
on-car brake lathes?
A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant
number of bench and on-car brake lathes. These tests measured critical performance
characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over
many uses. In each test, single pass lathe designs out performed the competitors. Single pass
brake lathes are more productive requiring less time to perform the same procedure.
- Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe?
A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The
debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other
brake concerns and comebacks.
- Q: What information needs to be documented on the Repair Order?
A: Any claim that is submitted using the labor operations in this bulletin, must have the Original
Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For
more information, refer to the "Repair Order Required Documentation" section of this bulletin.
All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited
where the repair does not comply with this procedure.
Brake Warranty
BRAKE WARRANTY
Brake Rotors:
- Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty.
Reference the vehicle's warranty guide for verification.
- Rotors should not be refinished or replaced during normal/routine pad replacement.
- Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type
noises and/or premature lining wear out.
- Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces
can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time
between stops.
- Rotors should not be refinished or replaced for rotor discoloration/hard spots.
- Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a
result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or
corrosion (Lot Rot).
- When rotor refinishing, only remove the necessary amount of material from each side of the rotor
and note that equal amounts of material do not have to be removed from both sides on any brake
system using a floating caliper.
- Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in).
Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should
be replaced.
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14323
- It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However,
caution should be exercised, as a variance in surface finish may cause a brake pull condition.
- New rotors should not be refinished before installation. Original equipment rotor surfaces are
ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new
rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the
hub, correct it using one of the following methods:
1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service
Procedure for Hubless Rotors" outlined in this
bulletin.
2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the
procedure outlined in this bulletin.
- Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the
rotor should be replaced.
Important If the Minimum Thickness specification is not visible on the rotor, reference Service
Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor
specifications.
Brake Pads:
Important When determining the warranty coverage (as an example) - if all four front or four rear
brake pads are excessively worn evenly, that would NOT be covered under warranty since this
type of wear is most likely due to driving habits or trailering. However, if the brake pads are
excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration
should be given to cover this under warranty since this type of wear is most likely due to poor
operation of other braking components.
- Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding
owner abuse, excessive trailering, or the situations that would not be considered normal use).
- Installation of new rotors does not require pad replacement. Do not replace pads unless their
condition requires it - excessively worn, damage or contaminated.
Brake Wear:
Several factors impact brake lining wear and should be taken into account when reviewing related
issues:
- heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving /
driver braking characteristics (left foot or two feet)
The following are conditions that may extend brake lining wear:
- light loads / highway driving / conservative driving / level terrain
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Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14324
Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information
Bulletin No.: 01-05-23-001B
Date: January 31, 2008
INFORMATION
Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction
Models: 2008 and Prior Passenger Cars
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
01-05-23-001A (Section 05 - Brakes).
This bulletin is being issued to update General Motors position on correcting brake rotor lateral
runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service
procedures).
Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those
specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation,
such as ABS pedal feedback, have been addressed before checking rotor runout.
Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or
less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until
now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or
to refinish the rotor using an on-vehicle brake lathe.
GM has approved a new technology for the correction of lateral runout on new or refinished rotors.
This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in)
or less requirement for lateral runout by installing a specially selected, tapered correction plate
between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of
an on-vehicle brake lathe to correct for lateral runout.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items which may be available from
other sources.
The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various
correction sizes, that will cover most current GM passenger car applications. It will also include a
Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful
tools.
Service Procedure
Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who
have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction
procedure:
The existing rotors must first be machined on an approved, well-maintained bench lathe to
guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note
that it is not necessary to machine new rotors.
Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel
Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining
washers provided in the kit. Do not reinstall the caliper or wheel at this time.
Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the
equivalent.
Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor
friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge.
Rotate the rotor and observe the total lateral runout.
Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal
and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is
.050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be
reassembled.
If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake
Align(R) Correction as follows:
Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor
to determine and locate the highest amount of lateral runout.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14325
Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud
relative to this location.
Remove the rotor.
Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application
Chart. Make sure the selection corrects the amount of runout that was diagnosed.
Never attempt to stack two or more Correction Plates together on one hub.
Never attempt to re-use a previously installed Correction Plate.
Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle
between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned
with the noted location of the "high spot" on the vehicle hub and marked wheel stud.
Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be
sure to install the rotor onto the hub in the same location as identified in Step 7.
The rotor should then be secured onto the hub and tightened to the proper specification. The rotor
should be dial indicated once more to assure that the rotor is now within specification.
The brake system is now ready for the remaining service and assembly. Once the caliper has been
installed, check to ensure that the rotor rotates freely.
Parts Information
Brake Align(R) Runout Correction Plates are available through the suppliers shown.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14326
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14327
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14328
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 14329
Brake Align Order Form
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Page 14330
Brake Rotor/Disc: Specifications
Front Brakes
Rotor Discard Thickness .....................................................................................................................
............................................... 28.6 mm (1.126 in) Rotor Maximum Allowable Assembled Lateral
Runout ..................................................................................................................... 0.06 mm (0.002
in) Rotor Maximum Allowable Scoring
................................................................................................................................................... 1.50
mm (0.059 in) Rotor Maximum Thickness Variation
.............................................................................................................................................. 0.025
mm (0.001 in) Rotor Minimum Allowable Thickness after Refinishing
.................................................................................................................... 29.0 mm (1.142 in) Rotor
Thickness - New ..................................................................................................................................
........................................ 30 mm (1.181 in)
Rear Brake Rotors
Rotor Discard Thickness* ....................................................................................................................
................................................ 9.0 mm (0.354 in) Rotor Maximum Allowable Assembled Lateral
Runout ..................................................................................................................... 0.06 mm (0.002
in) Rotor Maximum Allowable Scoring
................................................................................................................................................... 1.50
mm (0.059 in) Rotor Maximum Allowable Thickness Variation
............................................................................................................................. 0.025 mm (0.001
in) Rotor Minimum Allowable Thickness after Refinishing
.................................................................................................................... 9.35 mm (0.368 in) Rotor
Thickness - New ..................................................................................................................................
..................................... 11.0 mm (0.433 in)
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet
this specification. After refinishing the rotor, replace any rotor that does not meet the minimum
thickness specification.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction
Important:
*
Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* The indexing method of correcting assembled LRO is most effective when the LRO specification
is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used
to achieve the best possible match of high spots to low spots between related components. Refer
to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) .
* The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to
correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor
Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral
Runout Correction - Correction Plates) .
* The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) .
If the assembled LRO cannot be corrected using these methods, then other components must be
suspected as causing and/or contributing to the LRO concern.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14333
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Correction Plates
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Tools Required
* J 39544-KIT Complete Torque Socket Set-10 Pieces, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
*
Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor
assembled LRO measurement procedure, to face
upward.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's
instructions, which has a specification closest to the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003
in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm
(0.006 in) correction plate would be used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14334
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during
the brake rotor assembled LRO measurement
procedure.
Important: *
Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO.
* Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in
an attempt to correct brake rotor assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was
positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for
proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and
install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 11. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14335
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing
Brake Rotor Assembled Lateral Runout Correction - Indexing
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
*
Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor
to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a
different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14336
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in
order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14337
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On
Vehicle Lathe
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Tools Required
J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14338
Brake Rotor/Disc: Testing and Inspection
Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* The indexing method of correcting assembled LRO is most effective when the LRO specification
is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used
to achieve the best possible match of high spots to low spots between related components. Refer
to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) .
* The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to
correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor
Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral
Runout Correction - Correction Plates) .
* The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) .
If the assembled LRO cannot be corrected using these methods, then other components must be
suspected as causing and/or contributing to the LRO concern.
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Tools Required
* J 39544-KIT Complete Torque Socket Set-10 Pieces, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14339
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor
assembled LRO measurement procedure, to face
upward.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's
instructions, which has a specification closest to the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003
in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm
(0.006 in) correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during
the brake rotor assembled LRO measurement
procedure.
Important: *
Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO.
* Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in
an attempt to correct brake rotor assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was
positioned to face upward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14340
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for
proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and
install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 11. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Correction - Indexing
Brake Rotor Assembled Lateral Runout Correction - Indexing
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14341
Thickness Variation Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor
to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a
different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14342
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Tools Required
J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Measurement
Brake Rotor Assembled Lateral Runout Measurement
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 41013 Rotor Resurfacing Kit
* J 42450-A Wheel Hub Resurfacing Kit
* J 45101 Hub and Wheel Runout Gage
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14343
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or
contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which
could lead to brake pulsation.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no
foreign particles, corrosion, rust, or debris
remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these
conditions, perform the following steps:
1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (See: Service
and Repair/Removal and Replacement/Front
Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and
Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating
surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol,
or an equivalent approved brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1),
and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14344
Wheel Removal and Installation .
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9.
If the brake rotor meets the following criteria, proceed to step 10.
* The rotor is within specifications and is being REUSED.
* The rotor has NOT been refinished.
* The rotor does NOT exhibit thickness variation exceeding the maximum allowable level.
10. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
13. If the brake rotor assembled LRO is within specifications, proceed to step 18.
If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true
parallelism. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures) . After
refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
15. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled
Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Brake Rotor Surface and Wear Inspection
Brake Rotor Surface and Wear Inspection
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14345
Caution: Refer to Brake Dust Caution .
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface
Conditions:
* Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface
rust and/or pitting must be removed by refinishing the rotor.
* Cracks and/or heat spots
* Excessive blueing discoloration
4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions,
the rotor requires refinishing or replacement.
5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch,
measure and record the scoring depth of any grooves
present on the rotor friction surfaces.
6. Compare the groove scoring depth recorded to the following specification:
Brake rotor maximum allowable scoring: 1.50 mm (0.059 in)
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is
present, the rotor requires refinishing or
replacement.
Brake Rotor Thickness Measurement
Brake Rotor Thickness Measurement
Caution: Two different designs of the front brake rotors and front brake pads are used on this
vehicle. Do NOT interchange first design and second design parts, or a loss of braking and
personal injury could occur.
Caution: Refer to Brake Dust Caution .
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch,
measure and record the thickness of the brake rotor at
four or more points, evenly spaced around the rotor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 14346
Ensure that the measurements are only taken within the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each
measurement.
4. Compare the lowest thickness measurement recorded to the specifications listed in Disc Brake
Component Specifications (See:
Specifications/Disc Brake Component Specifications) .
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable
thickness after refinishing specification, the rotor may be
able to be refinished, depending upon surface and wear conditions which may be present.
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable
thickness after refinishing specification, the rotor may
not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness
specification, the rotor requires replacement.
Brake Rotor Thickness Variation Measurement
Brake Rotor Thickness Variation Measurement Caution: Refer to Brake Dust Caution .
Important: Any disc brake rotor that exhibits thickness variation exceeding the maximum
acceptable level must be refinished or replaced. Thickness variation exceeding the maximum
acceptable level can cause brake pulsation.
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch,
measure and record the thickness of the brake rotor at
4 or more points, evenly spaced around the rotor. Ensure that the measurements are only taken
within the friction surfaces and that the micrometer is positioned the same distance from the outer
edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to
obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the
following specification:
Brake rotor maximum allowable thickness variation: 0.02 mm (0.001 in)
Important: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of
the rotor must be measured to ensure optimum performance of the disc brakes.
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires
refinishing or replacement.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures
Brake Rotor/Disc: Procedures
Brake Rotor Refinishing
Tools Required
* J 41013 Rotor Resurfacing Kit
* J 42450-A Wheel Hub Resurfacing Kit
Caution: Refer to Brake Dust Caution .
Important:
* The disc brake rotors do not require refinishing as part of routine brake system service. New disc
brake rotors do not require refinishing.
Do not refinish disc brake rotors in an attempt to correct the following conditions:
- Brake system noise - squeal, growl, groan
- Uneven and/or premature disc brake pad wear
- Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface
- Scoring of the disc brake rotor friction surface less than the maximum allowable specification
* Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow
the rotor to be refinished and remain above the minimum allowable thickness after refinish
specification. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if
one or more of the following conditions exist:
- Thickness variation in excess of the maximum allowable specification
- Excessive corrosion/rust and/or pitting
- Cracks and/or heat spots
- Excessive blueing discoloration
- Scoring of the disc brake rotor surface in excess of the maximum allowable specification
* Disc brake rotors may need to be refinished as part of the process for correcting brake rotor
assembled lateral runout (LRO) that exceeds the maximum allowable specification.
Important: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling.
This setup requires less cutting pressure, which will result in less vibration, and a better surface
finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following
instructions.
Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust
or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this
may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to
brake pulsation.
1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating
surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle
flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the
brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all
mounting attachments and adapters are
clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe
running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7.
Observe the witness mark on the brake rotor. If the witness mark extends approximately
three-quarters or more of the way around the brake rotor
friction surface on each side, the brake rotor is properly mounted to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor,
re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the
brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 14349
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake
rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Measurement) .
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled
Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Correction) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 14350
Brake Rotor/Disc: Removal and Replacement
Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing Caution: Refer to Road Test Caution .
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Front Brake Rotor Replacement
Front Brake Rotor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 14351
Rear Brake Rotor Replacement
Rear Brake Rotor Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 14352
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component
Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 08-05-26-001 > Jun > 08 > Brakes Rattle Noise From Rear of Vehicle
Backing Plate: Customer Interest Brakes - Rattle Noise From Rear of Vehicle
INFORMATION
Bulletin No.: 08-05-26-001
Date: June 11, 2008
Subject: Information on Rattle Type Noise Heard from Rear of Vehicle
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
If a customer comments on a rattle type noise that can be heard from the rear of the vehicle while
driving over sharp bumps, such as potholes or railroad tracks, this condition may be caused by the
parking brake shoe retaining clip becoming loose AND allowing the shoes to contact the support
plate.
If routine diagnosis using SI does not reveal any obvious cause, inspect the parking brake shoe to
make sure it is not loose in the retaining clip before replacing any suspension components. If it is
determined that the shoes are loose, replace the park brake support plate.
To reduce unnecessary warranty, please make every effort to inspect all components before
ordering any new parts.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 08-05-26-001 > Jun > 08 >
Brakes - Rattle Noise From Rear of Vehicle
Backing Plate: All Technical Service Bulletins Brakes - Rattle Noise From Rear of Vehicle
INFORMATION
Bulletin No.: 08-05-26-001
Date: June 11, 2008
Subject: Information on Rattle Type Noise Heard from Rear of Vehicle
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
If a customer comments on a rattle type noise that can be heard from the rear of the vehicle while
driving over sharp bumps, such as potholes or railroad tracks, this condition may be caused by the
parking brake shoe retaining clip becoming loose AND allowing the shoes to contact the support
plate.
If routine diagnosis using SI does not reveal any obvious cause, inspect the parking brake shoe to
make sure it is not loose in the retaining clip before replacing any suspension components. If it is
determined that the shoes are loose, replace the park brake support plate.
To reduce unnecessary warranty, please make every effort to inspect all components before
ordering any new parts.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important:
* Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
* The automated bleed procedure must be performed when a new brake pressure modulator valve
(BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake
fluid.
* The automated bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out away from the brake modulator assembly, which is then forced out at the
brake corners by the pressure bleeder.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and
Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as needed.
4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed
of the base hydraulic brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) .
6. Inspect the battery state of charge. Refer to Battery Inspection/Test . 7. Install a scan tool. 8.
Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps:
1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select
Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed
10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Important: *
Apply the brake pedal when instructed, using moderate effort.
* Ensure the pedal remains applied until instructed to release by the scan tool.
* Do not exceed the time period allowed by the scan tool for having the bleeder valves open.
* The bleed sequence for each corner is as follows:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14372
- Left front
- Right front
Right rear
- Left rear
11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated
bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble
Code (DTC) List - Vehicle to
diagnose the DTC.
13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect
for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15.
Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal
and Installation . 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder
Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master
Cylinder Reservoir Filling) .
19. Road test the vehicle while confirming the brake pedal remains high and firm.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14373
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
Important: If you have performed a brake master cylinder bench bleeding, disconnected the brake
pipes from the master cylinder, replaced the ABS pressure modulator valve, or disconnected the
jumper lines from the master cylinder to the ABS pressure valve, you MUST use the pressure
bleeding procedure to remove all the air from the system. Refer to Hydraulic Brake System
Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) (See: ) .
3. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian
P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains
at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
4. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 5.
Install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
7. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the
bleeder valve, then have the assistant slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air
has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left front hydraulic circuit, install
a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
18. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
19. Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
Important: If it is determined that air was induced into the system upstream of the ABS modulator
prior to servicing, the Antilock Brake System Automated Bleed Procedure (See: ) must be
performed.
20. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still
feels spongy after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
21. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14374
22. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 35589-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With
the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, replaced the ABS
pressure modulator valve, or disconnected the
brake lines between master cylinder and ABS on this vehicle, you must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11(R) GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
If removal of the reservoir cap is necessary, clean the outside of the reservoir on and around the
cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake
master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4.
Reconnect the brake pipe to the master cylinder port, and rotate the line at the master cylinder at
least 30 degrees, so that the line will be
positioned BELOW the MAX fill line on the brake master cylinder reservoir. Tighten the line nut
securely.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7.
Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds,
then repeat steps 3.5-3.7 until all air is purged from the same port of the master cylinder. 9. With
the front brake pipe installed securely to the master cylinder - after all air has been purged from the
front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.5-3.7,
ensuring that the line is rotated below the master cylinder MAX fill line.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly
tightened, and that they remain in their new rotated positions below the MAX fill line of the brake
fluid reservoir.
4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J
29532 , or equivalent. Add Delco Supreme 11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to
approximately the half-full point.
7. Connect the J 29532 , or equivalent, to the J 35589-A . 8. Charge the J 29532 , or equivalent, air
tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow
pressurized brake fluid to enter the brake system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R) GM P/N
12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
14. Repeat steps 11-13 for the LEFT FRONT wheel hydraulic circuit bleeder valve. 15. Loosen the
bleeder valve to purge air from the wheel hydraulic circuit. It is important that both bleeder valves
be open at the same time. Allow
fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve.
16. With the right rear and left front wheel hydraulic circuit bleeder valve tightened securely - after
all air has been purged from the right rear and left
front hydraulic circuit - install a proper box-end wrench onto the LEFT REAR and RIGHT FRONT
wheel hydraulic circuit bleeder valve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14375
17. Install a transparent hose over the end of the bleeder valve, then repeat step 15. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Loosen the rear master cylinder jumper line nut slightly (just enough to rotate the line), and
rotate the rear master cylinder hydraulic pipe back to
the original position, and tighten the line nut.
20. Reposition the front master cylinder jumper line to the original position in a similar manner to
step 19. 21. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or
equivalent, from the J 35589-A . 22. Remove the J 35589-A from the brake master cylinder
reservoir. 23. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme
11(R) GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
24. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 25. If the
brake pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure
(See: ) .
26. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
27. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14376
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and
Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and
Replacement/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Master Cylinder Overhaul (See: Brake Master Cylinder/Service and Repair/Overhaul) or Master
Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master
cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using
non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary.
Refer to Master Cylinder Reservoir Replacement (See: Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) . Replace the brake
master cylinder reservoir cap diaphragm.
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Front Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Front Brake
Caliper Overhaul) or Front Brake Caliper Replacement (See: Brake Caliper/Service and
Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake
Caliper Overhaul) or Rear Brake Caliper Replacement (See: Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The
diaphragm may have allowed the moisture or
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 14377
particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canada P/N 992667) or
equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information
Brake Caliper: Technician Safety Information
Caliper Piston Removing Caution
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information > Page 14382
Brake Caliper: Vehicle Damage Warnings
Brake Caliper Notice
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Page 14383
Brake Caliper: Testing and Inspection
Brake Caliper Inspection
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores:
The movement of the caliper pistons into the caliper bores should be smooth and even. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement
Brake Caliper: Removal and Replacement
Front Brake Caliper Replacement
Front Brake Caliper Replacement
Rear Brake Caliper Replacement
Rear Brake Caliper Replacement
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14386
Caution: Refer to Brake Dust Caution . Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway
between the maximum-full point and the minimum allowable level, then no brake fluid needs to be
removed from
the reservoir before proceeding. If the brake fluid level is higher than midway between the
maximum-full point and the minimum allowable level, then remove brake fluid to the midway point
before proceeding.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 4. Remove the
rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation . 5. Hand
tighten 2 wheel lug nuts to retain the rotor to the hub.
6. Install a large C-clamp (3) over the top of the brake caliper (2) and against the back of the
outboard brake pad. 7. Tighten the C-clamp (3) until the caliper piston is pushed into the caliper
bore enough to slide the caliper off the rotor. 8. Remove the C-clamp (3) from the caliper.
9. Remove the brake hose-to-caliper bolt (1) from the caliper.
Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper
and/or the brake hose end.
10. Plug the opening in the rear brake hose (2) to prevent excessive brake fluid loss and
contamination.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14387
11. Remove the caliper bolts (1 and 3). 12. Remove the caliper (3) from the rotor (4) and the caliper
bracket (1). 13. Inspect the caliper bracket bolt boots on the caliper bracket for the following
conditions:
* Cuts
* Tears
* Deterioration Replace any damaged caliper bracket bolt boots. Refer to Rear Disc Brake
Hardware Replacement (See: Disc Brake System/Service and Repair/Rear Disc Brake Hardware
Replacement) .
14. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new caliper
bolts, including bushings, when installing caliper.
Installation Procedure
1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are
in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14388
2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads. 3.
Lubricate the 2 bolt boots (13 and 4) in the caliper bracket (12). Use silicone grease.
Notice: Refer to Fastener Notice .
4. Install the caliper bolts (1 and 3). Ensure that the bolt boots fit securely in the groove of the
caliper bolts. Be sure not to pinch or tear the boots. If
the boots are damaged, they must be replaced.
Tighten the bolts to 44 N.m (32 lb ft).
Important: Install NEW copper gaskets.
5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose
(2). 6. Install the brake hose-to-caliper bolt to the brake caliper.
Tighten the bolt to 54 N.m (40 lb ft).
7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the rear tire and the wheel
assembly. Refer to Tire and Wheel Removal and Installation . 9. Lower the vehicle.
10. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder
Reservoir Filling (See: Brake Master Cylinder/Service
and Repair/Procedures/Master Cylinder Reservoir Filling) .
11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake
Bleeding/Service and Repair)Hydraulic Brake System
Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
12. Inspect the hydraulic brake system for brake fluid leaks.
Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement
Removal Procedure Caution: Refer to Brake Dust Caution .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14389
may cause damage to the brake hose and in turn may cause a brake fluid leak.
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics
wire or equivalent. It is not necessary to disconnect
the hydraulic brake flexible hose from the caliper. Refer to Front Brake Caliper Replacement (See:
Front Brake Caliper Replacement) .
2. Remove the front brake pads.
3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1).
Installation Procedure
Important: To ensure that the proper clamp load will be present when installed. It is imperative that
the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of
all debris and inspected before proceeding with installation.
1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the
knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488) or equivalent,
to the threads of the brake caliper bracket bolts (2).
Notice: Refer to Fastener Notice .
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten the caliper bracket bolts to 180 N.m (133 lb ft).
4. Install the front brake pads. 5. Install the caliper. Refer to Front Brake Caliper Replacement
(See: Front Brake Caliper Replacement) .
Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement
Removal Procedure Caution: Refer to Brake Dust Caution .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics
wire or equivalent. It is not necessary to disconnect
the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (See:
Rear Brake Caliper Replacement) .
2. Remove the rear brake pads.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14390
3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1).
Installation Procedure
Important: To ensure that the proper clamp load will be present when installed. It is imperative that
the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of
all debris and inspected before proceeding with installation.
1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the
knuckle. 2. Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the
threads of the brake caliper bracket bolts (2).
Notice: Refer to Fastener Notice .
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten the caliper bracket bolts to 120 N.m (88 lb ft).
4. Install the rear brake pads. 5. Install the caliper. Refer to Rear Brake Caliper Replacement (See:
Rear Brake Caliper Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14391
Brake Caliper: Overhaul
Front Brake Caliper Overhaul
Front Brake Caliper Overhaul
Tools Required
* J 8092 Driver Handle 3/4 inch-10
* J 45863 Dust Seal Installer
Caution: Refer to Brake Fluid Irritant Caution .
Disassembly Procedure
1. Drain all the brake fluid from the caliper.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while
applying compressed air. This could result in serious injury.
Important: In the following service procedure, the caliper piston may become damage when it is
removed from the brake caliper assembly. If this happens, DO NOT reuse the piston. Discard and
replaced with new.
2. Install the brake caliper in a suitable holding devise. 3. Insert a piece of wood in the brake
caliper. 4. Cover the brake caliper with a shop towel. 5. Using compressed filtered, non-lubricated
air, apply the air to the remove the pistons from the brake caliper.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14392
6. If one of the pistons fails to be removed from the brake caliper, perform the following steps.
1. Reposition the piston that has been removed back in the brake caliper. 2. Using a small block of
wood and a C-clamp, slowly tighten the C-clamp until the piston it is half way in the brake caliper. It
does not have to
be fully seated.
3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover
the brake caliper with a shop towel. 5. Using compress filtered, non lubricated air, apply the air to
the remove the pistons from the brake caliper.
7. Remove the pistons (3) from the caliper bores. 8. Remove the piston seals (2) from the caliper
bores. Do not use a metal tool. 9. Remove the bleeder valve cap (5).
10. Remove the bleeder valve (6) from the caliper housing (1). 11. Clean the bleeder valve, the
caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow
out the brake fluid
passages. Use dry and filtered compressed air.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14393
12. Remove the boots from the caliper bores. Do not scratch the caliper bores. 13. Replace the
pistons or the caliper if any of the following conditions exist:
* Scoring in the caliper bores
* Corrosion in the caliper bores
* Pitting in the caliper bores
* Damage to the pistons (phenolic)
14. Clean the brake caliper assembly with denatured alcohol. 15. Dry with filtered , lubricated
compressed air.
Assembly Procedure
Important: When applying the clean brake fluid to the piston bores and pistons, only apply the
brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons
DO NOT become contaminated with dirt or other foreign material.
1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14394
2. Install the piston seal in the brake caliper.
3. Install the dust seal on the piston.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14395
Important: Position the piston in the bore so that it is straight and level.
4. Install the piston in the brake caliper.
5. Position a piece of wood across the piston to be installed. 6. Applying equal pressure by hand
while pushing down, install the piston in the bore. 7. Remove the piece of wood.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14396
8. Using the J 8092 (1) and the J 45863 (2) , install the piston dust seal in the brake caliper.
Notice: Refer to Fastener Notice .
9. Install the bleeder valve in the brake caliper housing.
Tighten the bleeder valve to 13 N.m (115 lb in).
10. Install bleeder valve cap.
Rear Brake Caliper Overhaul
Rear Brake Caliper Overhaul
Removal Procedure Caution: Refer to Brake Dust Caution .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14397
Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Remove the rear brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough
air to ease the pistons out of the bores. If the pistons are blown out, even with the padding
provided, it may be damaged.
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air
into the caliper bore through the fluid inlet hole.
3. Remove the retaining ring that secures the dust boot to the caliper housing.
4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot
seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore .
Discard the piston seal.
Important: Do not use abrasives to clean the brake caliper piston.
6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured
alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with
non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust,
and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt
to remove the imperfection with a fine emery paper. If the imperfection
cannot be removed, replace the caliper assembly.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Replacement > Page 14398
10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper
bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or
damage to the chrome plating. Replace the caliper piston if any of these conditions exist.
Installation Procedure
1. Lubricate the new piston seal (4) with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Delco
Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from
a clean, sealed
brake fluid container onto the outer surface area of the caliper piston (3).
4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust
boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the
caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore.
8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Install the bleeder
valve and cap to the caliper and tighten the valve securely.
10. Install the rear brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM
Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Powertrain Component Views
Brake Fluid Level Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Powertrain Component Views > Page 14406
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Rear of Engine Compartment
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Right Front of the Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Powertrain Component Views > Page 14407
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 14408
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 14409
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from brake fluid level sensor.
2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining
tabs on the end of the brake fluid level sensor (1) and
press the sensor through the reservoir to remove.
Installation Procedure
1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor
retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement
Brake Hose/Line: Service and Repair Brake Pipe Replacement
Brake Pipe Replacement
Tools Required
J 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution .
Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any
other pipe is not recommended and may cause brake system failure. Carefully route and retain
replacement brake pipes. Always use the correct fasteners and the original location for
replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to
the brake pipes and cause brake system failure.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important: When servicing brake pipes, note the following:
*
If sectioning brake pipe, use replacement pipe of the same type and outside diameter.
* Use fittings of the appropriate size and type.
* Only create flares of the same type or design as originally equipped on the vehicle.
1. Inspect the section of brake pipe to be replaced. 2. Release the brake pipe to be replaced from
the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary.
* Allow adequate clearance in order to maneuver the J 45405 .
* Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5.
Add to the measurement taken the appropriate additional length required for each flare to be
created.
6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the
pipe length.
6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the
measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate
size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake
pipe size.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14414
9. Strip the nylon coating from the brake pipe ends to be flared, if necessary.
* Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the tool
rollers.
6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
* Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
* While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the
metal surface of the brake pipe.
* Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains
against the tool roller ledges.
* After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface
is exposed.
* Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose
remnants of the nylon coating have been removed from the brake pipe.
* Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J
45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe
and the J 45405 of lubricant, contaminants, and debris.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14415
13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install
the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the
counterbores of both dies facing the forming ram.
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the
enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14416
20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic
fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it
bottoms against the die cage.
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever
of the J 45405 until the forming mandrel bottoms
against the clamping dies.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract. 25. Loosen the die clamping screw and remove the dies and pipe.
26. If necessary, lightly tap the dies until the die halves separate.
27. Inspect the brake pipe flare for correct shape and diameter (a).
7.10 mm (0.279 in) +/- 0.18 mm (0.007 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
28. If necessary, using the removed section of pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or
vibrating components.
29. Install the pipe to the vehicle with the appropriate brake pipe unions as required. 30. If
previously released, secure the brake pipe to the retainers. 31. Bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and
Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
32. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14417
Brake Hose/Line: Service and Repair Front Brake Hose Replacement
Front Brake Hose Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the
front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 3. Clean all dirt
and foreign material from the brake hoses and brake pipe fitting.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid
loss and contamination.
4. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose,
then cap or plug the brake pipe fitting end.
Do not bend the brake pipe or the bracket.
5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the hose from
the bracket.
7. Remove the brake hose to caliper bolt (4) from the brake caliper (2). 8. Remove the brake hose
(5) from the brake caliper (2). 9. Remove and discard the two copper brake hose gaskets (3).
These gaskets may be stuck to the brake caliper and/or the brake hose end.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14418
Important: Install NEW copper brake hose gaskets (3).
1. Assemble the NEW copper brake hose gaskets (3), and the brake hose bolt (4) to the brake
hose.
Notice: Refer to Fastener Notice .
2. Install the brake hose to caliper bolt to the brake caliper.
Tighten the brake hose to brake caliper bolt to 54 N.m (40 lb ft).
3. With the weight of the vehicle on the suspension, install the brake hose into the bracket.
There should not be any kinks in the hose. Align the hose fitting with the notch in the bracket. Use
the hose paint stripe as a visual aid.
4. Install the retainer onto the hose fitting at the bracket. 5. Remove the rubber cap or plug from the
exposed brake pipe fitting end.
6. Connect the brake pipe fitting to the brake hose:
* Use a backup wrench on the hose fitting.
* Do not bend the bracket or pipe.
Tighten the brake pipe fitting to 18 N.m (13 lb ft).
7. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 8.
Ensure that the hose does not make contact with any part of the suspension. Check the hose in
extreme right and extreme left turn conditions. If the
hose makes contact, remove the hose and correct the condition.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
Brake Bleeding/Service and Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
10. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14419
Brake Hose/Line: Service and Repair Rear Brake Hose Replacement
Rear Brake Hose Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the
rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 3. Clean all dirt
and foreign material from the brake hoses and brake pipe fitting.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid
loss and contamination.
4. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose,
then cap or plug the brake pipe fitting end.
Do not bend the brake pipe or the bracket.
5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the hose from
the bracket.
7. Remove the brake hose to caliper bolt (1) from the brake caliper. 8. Remove the brake hose (2)
from the brake caliper. 9. Remove and discard the two copper brake hose gaskets (4). These
gaskets may be stuck to the brake caliper and/or the brake hose end.
Installation Procedure
Important: Install NEW copper brake hose gaskets (4).
1. Assemble the NEW copper brake hose gaskets (4), and the brake hose bolt (1) to the brake
hose (2).
Notice: Refer to Fastener Notice .
2. Install the brake hose to caliper bolt (1) to the brake caliper.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 14420
Tighten the brake hose to brake caliper bolt to 54 N.m (40 lb ft).
3. With the weight of the vehicle on the suspension, install the brake hose into the bracket.
There should not be any kinks in the hose. Align the hose fitting with the notch in the bracket. Use
the hose paint stripe as a visual aid.
4. Install the retainer onto the hose fitting at the bracket. 5. Remove the rubber cap or plug from the
exposed brake pipe fitting end. 6. Connect the brake pipe fitting to the brake hose:
* Use a backup wrench on the hose fitting.
* Do not bend the bracket or pipe.
Tighten the brake pipe fitting to 18 N.m (13 lb ft).
7. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 8.
Ensure that the hose does not make contact with any part of the suspension. If the hose makes
contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic
Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
10. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Replacement
Brake Pressure Modulator Valve Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page
14425
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page
14426
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Bracket Replacement
Brake Pressure Modulator Valve Bracket Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures
Brake Master Cylinder: Procedures
Master Cylinder Bench Bleeding
Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the
primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install
suitable fittings to the master cylinder ports that match the type of flare seat required and also
provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master
cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder
reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian
P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully
submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the
primary piston as far as it will travel, a depth of about 25 mm (1 in), several times.
Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary
pistons, the effort required to depress the primary piston will increase and the amount of travel will
decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir.
10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the
transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth
to prevent brake
fluid spills.
12. Remove the master cylinder from the vise.
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake
fluid level is at or below the half-full point during routine fluid checks, the brake system should be
inspected for wear and possible
brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or
brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the
maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not
recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder
reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing
the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14431
clean, sealed brake fluid container.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14432
Brake Master Cylinder: Removal and Replacement
Master Cylinder Reservoir Replacement
Master Cylinder Reservoir Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement (See:
Master Cylinder Replacement) . 2. Secure the master cylinder in a vise. Do not clamp the master
cylinder body, secure only at the flange.
3. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining
tabs on the end of the brake fluid level sensor (1) and
press the sensor through the reservoir to remove.
4. Carefully tap out the reservoir retaining pins. 5. Remove the reservoir from the master cylinder
by pulling the reservoir straight up and away from the cylinder. 6. Remove the seals from the
master cylinder.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14433
1. Inspect the reservoir (1) for cracks or deformation. If found, replace the reservoir. 2. Clean the
reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air.
4. Lubricate the new seals (2) and the outer surface area of the reservoir-to-housing barrels with
Delco Supreme 11(R), GM P/N 12377967
(Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
5. Install the lubricated seals (2), make sure they are fully seated. 6. Install the reservoir (1) to the
master cylinder, by pressing the reservoir straight down on the master cylinder until the pin holes
are aligned.
7. Carefully tap the reservoir retaining pins into place to secure the reservoir. 8. Place the brake
fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove
the master cylinder from the vise.
10. Install master cylinder to the vehicle. Refer to Master Cylinder Replacement (See: Master
Cylinder Replacement) .
Master Cylinder Replacement
Master Cylinder Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14434
1. Disconnect the electrical connector from the brake fluid level sensor. 2. Disconnect the brake
pipes from the master cylinder.
Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent
brake fluid loss and contamination.
3. Plug the open brake pipe ends. 4. Remove master cylinder mounting nuts. 5. Remove the
master cylinder from the vehicle. 6. Drain the master cylinder reservoir of all brake fluid.
Installation Procedure
1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (See:
Procedures/Master Cylinder Bench Bleeding) . 2. Install the master cylinder to the vacuum brake
booster.
Notice: Refer to Fastener Notice .
3. Install the master cylinder mounting nuts.
Tighten the master cylinder mounting nuts to 33 N.m (24 lb ft).
4. Remove the plugs from the brake pipes 5. Connect the brake pipes to the master cylinder.
Tighten the brake pipe fittings at the master cylinder to 18 N.m (13 lb ft).
6. Connect the electrical connector to the brake fluid level sensor. 7. Bleed the brake system. Refer
to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic
Brake System
Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14435
Brake Master Cylinder: Overhaul
Master Cylinder Overhaul Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Disassembly Procedure
1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder Replacement (See:
Removal and Replacement/Master Cylinder
Replacement) .
2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the
primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around
the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and
diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following
conditions. If any of these conditions are present, replace the affected components.
* Cuts or cracks
* Nicks or deformation
6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder
Reservoir Replacement (See: Removal and
Replacement/Master Cylinder Reservoir Replacement) .
7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston
retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet
ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet
port, in order the remove
the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring.
10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from
the secondary piston.
Assembly Procedure
Important: Do not use abrasives to clean the brake master cylinder bore.
1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return
spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet
ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion.
Replace the master cylinder if any of these conditions exist.
3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4.
Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the
individual overhaul components with Delco Supreme
11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean,
sealed brake fluid container.
5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the
secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the
cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 14436
8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston
retainer. 9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder
Reservoir Replacement (See: Removal and
Replacement/Master Cylinder Reservoir Replacement) .
10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the
vehicle. Refer to Master Cylinder Replacement (See: Removal and Replacement/Master Cylinder
Replacement) .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator >
Component Information > Service and Repair
Parking Brake Actuator: Service and Repair
Parking Brake Actuator Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear tire
and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Relieve the park brake system tension at the equalizer assembly. 4. Remove the rear caliper
bracket. Refer to Rear Brake Caliper Bracket Replacement (See: Disc Brake System/Brake
Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement) .
5. Remove the rear rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and
Replacement/Rear Brake Rotor Replacement) .
6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. Refer to
Parking Brake Rear Cable Replacement (Z7U) (See:
Parking Brake Cable/Service and Repair/Parking Brake Rear Cable Replacement (Z7U)) .
7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the
rear wheel. 8. Remove the rear hub. Refer to Rear Wheel Bearing and Hub Replacement .
The rear hub, backing plate, park brake cable bracket, and park brake actuator will be removed as
an assembly.
9. Remove the 2 retainers (9) and the park brake cable bracket (8) from the park brake actuator
(4). Position the rear hub aside .
10. Remove the park brake shoe and actuator (4) from the backing plate (7). 11. Separate the
actuator (4) from the park brake shoe .
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator >
Component Information > Service and Repair > Page 14441
1. Assemble the actuator (4) to the park brake shoe. 2. Install the park brake shoe and actuator (4)
onto the backing plate (7). 3. Position the park brake shoe, actuator (4), and backing plate (7) over
the rear hub.
Notice: Refer to Fastener Notice .
4. Install the park brake cable bracket (8) and the 2 retainers (9)
Tighten the bracket retainers to 14 N.m (124 lb in).
5. Install the rear hub. Refer to Rear Wheel Bearing and Hub Replacement .
The rear hub, backing plate, park brake cable bracket, and park brake actuator will be installed as
an assembly.
6. Install and connect the rear park brake cable to the bracket at the rear wheel. Refer to Parking
Brake Rear Cable Replacement (Z7U) (See:
Parking Brake Cable/Service and Repair/Parking Brake Rear Cable Replacement (Z7U)) .
7. Connect the park brake cable return spring to the park brake actuator and bracket at the rear
wheel. 8. Install the rear rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake
System/Brake Rotor/Disc/Service and Repair/Removal and
Replacement/Rear Brake Rotor Replacement) .
9. Install the rear caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (See: Disc
Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement) .
10. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
11. Adjust the park brake system. Refer to Park Brake Adjustment (See: Adjustments) . 12. Lower
the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement
Parking Brake Cable: Service and Repair Parking Brake Front Cable Replacement
Parking Brake Front Cable Replacement
Tools Required
J 37043 Parking Brake Cable Release Tool
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Relieve the cable tension at the park brake equalizer.
3. Disconnect the front cable from the connector (2).
4. Remove the front cable from the equalizer. 5. Remove the front cable from the cable guides. 6.
Lower the vehicle. 7. Remove the left side closeout/insulator panel. Refer to Instrument Panel
Insulator Panel Replacement - Left Side . 8. Remove the lower center pillar panel on the left side
and the left side carpet retainers. Refer to Center Pillar Lower Trim Panel Replacement . 9. Fold
back the carpeting in order to gain access to the front park brake cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14446
10. Remove the retaining clip and disconnect the cable from the clevis. 11. Use the J 37043 to
release the retainer holding cable to the bracket on the pedal assembly. 12. Remove the front
cable from the vehicle.
Note routing of the cable for installation.
Installation Procedure
1. Install the front cable into the vehicle as noted in the removal procedure. 2. Install the front park
brake cable into the bracket on the park brake pedal assembly.
3. Insert the cable button end into the clevis and install the retaining clip. 4. Reposition the
carpeting properly. 5. Install the left side carpet retainers and the lower center pillar trim panel on
the left side . Refer to Center Pillar Lower Trim Panel Replacement . 6. Install the left side
closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side . 7.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 8. Install the front park
brake cable through the park brake cable guides. 9. Install the front park brake cable into the
equalizer.
10. Connect the front park brake cable (1) to the rear cable (3) at the connector clip (2).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14447
11. Tighten the nut on the equalizer (2) in order to remove slack in the cable. 12. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14448
Parking Brake Cable: Service and Repair Parking Brake Rear Cable Replacement (Z7U)
Parking Brake Rear Cable Replacement (Z7U)
Tools Required
J 37043 Parking Brake Cable Release Tool
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Relieve the
park brake cable tension at the equalizer. 3. Disconnect the front cable from the rear cable that is
to be replaced.
* For the right rear cable, disconnect the cable (3) from the clip (2).
* For the left rear cable, fully remove the equalizer nut from the equalizer stud, which is part of the
left rear cable.
4. Disconnect the retainer (1) that holds the cable to the support bracket. Use the J 37043 to
release the retainer.
5. Disconnect the park brake cable from the actuator lever. 6. Remove cable retaining pin from the
support bracket and remove the park brake cable.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14449
1. Position the park brake cable into the support bracket and install the cable retaining pin. 2. Install
the park brake cable to the actuator lever.
3. Connect the retainer (1) that holds the cable to the support bracket. 4. Connect the rear cable to
the front cable.
* For the right rear cable, connect the cable (3) to the clip (2).
* For the left rear cable, install the equalizer stud to the equalizer nut, which is part of the equalizer
assembly.
5. Adjust the park brake. Refer to Park Brake Adjustment (See: Adjustments) . 6. Lower the
vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14450
Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement
Park Brake Cable Equalizer Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the left rear park brake cable and adjustment stud assembly from the equalizer
assembly by removing the equalizer nut from the
adjustment stud.
3. Disconnect the front park brake cable (1) from the right rear cable (3) at the connector clip (2).
4. Remove the equalizer assembly from the front park brake cable. Insert a flat-bladed tool into the
equalizer and lightly twist to reposition the
equalizer retaining tab. This will release the assembly from the cable.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 14451
1. Install the equalizer assembly to the front park brake cable.
2. Connect the front brake cable (1) to the right rear cable (3) at the connector clip (2). 3. Connect
the left rear brake cable and adjustment stud assembly to the equalizer assembly by installing the
adjustment stud to the equalizer nut. 4. Adjust the Park Brake System. Refer to Park Brake
Adjustment (See: Adjustments) . 5. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair
Parking Brake Lever: Service and Repair
Parking Brake Lever Pedal Assembly Replacement
Tools Required
J 37043 Parking Brake Cable Release Tool
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Relieve the cable tension at the park brake equalizer.
3. Disconnect the front cable from the connector (2). 4. Lower the vehicle. 5. Remove the left side
closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side . 6.
Remove the left side front carpet retainers. Refer to Center Pillar Lower Trim Panel Replacement .
7. Disconnect the electrical connector at the park brake switch.
8. Remove the 3 park brake pedal assembly retraining nuts from the body mounting studs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 14455
9. Remove the retaining clip and disconnect the cable button from the clevis.
10. Use the J 37043 to release and remove cable from the bracket on the pedal assembly. 11.
Remove the park brake pedal assembly.
Installation Procedure
1. Install the park brake assembly onto the body mounting studs.
Notice: Refer to Fastener Notice .
2. Install the 3 park brake pedal assembly retaining nuts.
Tighten the nuts to 25 N.m (18 lb ft).
3. Install the front park brake cable into the bracket on the park brake pedal assembly.
4. Insert the cable button into the clevis and install the retaining clip. 5. Connect the electrical
connector to the park brake switch. 6. Reposition the carpeting properly. 7. Install the left side
carpet retainers and the lower center pillar trim panel on the left side. Refer to Center Pillar Lower
Trim Panel Replacement . 8. Install the left side closeout/insulator panel. Refer to Instrument Panel
Insulator Panel Replacement - Left Side . 9. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle .
10. Install the front park brake cable through the park brake cable guides.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 14456
11. Connect the front park brake cable (1) to the rear cable (3) at the connector clip (2).
12. Tighten the nut on the equalizer in order to remove slack in the cable. 13. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations
Parking Brake Release Switch: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Page 14460
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > Customer Interest: > 08-05-26-001 > Jun > 08 > Brakes - Rattle Noise From
Rear of Vehicle
Parking Brake Shoe: Customer Interest Brakes - Rattle Noise From Rear of Vehicle
INFORMATION
Bulletin No.: 08-05-26-001
Date: June 11, 2008
Subject: Information on Rattle Type Noise Heard from Rear of Vehicle
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
If a customer comments on a rattle type noise that can be heard from the rear of the vehicle while
driving over sharp bumps, such as potholes or railroad tracks, this condition may be caused by the
parking brake shoe retaining clip becoming loose AND allowing the shoes to contact the support
plate.
If routine diagnosis using SI does not reveal any obvious cause, inspect the parking brake shoe to
make sure it is not loose in the retaining clip before replacing any suspension components. If it is
determined that the shoes are loose, replace the park brake support plate.
To reduce unnecessary warranty, please make every effort to inspect all components before
ordering any new parts.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-05-26-001 > Jun > 08 > Brakes - Rattle
Noise From Rear of Vehicle
Parking Brake Shoe: All Technical Service Bulletins Brakes - Rattle Noise From Rear of Vehicle
INFORMATION
Bulletin No.: 08-05-26-001
Date: June 11, 2008
Subject: Information on Rattle Type Noise Heard from Rear of Vehicle
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
If a customer comments on a rattle type noise that can be heard from the rear of the vehicle while
driving over sharp bumps, such as potholes or railroad tracks, this condition may be caused by the
parking brake shoe retaining clip becoming loose AND allowing the shoes to contact the support
plate.
If routine diagnosis using SI does not reveal any obvious cause, inspect the parking brake shoe to
make sure it is not loose in the retaining clip before replacing any suspension components. If it is
determined that the shoes are loose, replace the park brake support plate.
To reduce unnecessary warranty, please make every effort to inspect all components before
ordering any new parts.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps
Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL
ON P0116/P1400 Set In Very Cold Temps
TECHNICAL
Bulletin No.: 10-06-04-008A
Date: January 24, 2011
Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When
Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant
Temperature (ECT) Sensor and Engine Coolant Heater Cord)
Models:
2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010
Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer
2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010
GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with
V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF,
LMG, LY2, LY5, LY6 Please Refer to GMVIS
Attention:
To properly correct this condition, you must follow both of the procedures to relocate the ECT
sensor and the engine coolant heater cord.
Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the
Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008
(Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting
the vehicle when they were using the engine coolant heater in very cold ambient temperatures.
This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder.
The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History.
Cause
This condition may be caused by the engine control module (ECM) determining that the ignition
OFF time requirement has been met at start-up and interpreting the temperature difference
between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor
as being outside of a calibrated range.
Correction
Important DO NOT replace the ECM for this condition.
Relocating the ECT Sensor
1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle.
Refer to Diagnostic System Check - Vehicle in SI.
‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater,
proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the
engine coolant heater, refer to Diagnostic Trouble Code (DTC)
List - Vehicle in SI.
3. Turn OFF the ignition.
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14479
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14480
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14481
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14482
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14488
under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator
are still hot.
4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean
drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle.
Refer to Cooling System Draining
and Filling in SI.
7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp
on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the
radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor.
10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J
38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle.
13. Disconnect the wiring harness connector from the ECT sensor (2).
14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding
size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with
sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT
sensor in the hole of the cylinder head where the plug was removed.
Tighten Tighten to 20 Nm (15 lb ft).
18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or
an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was
removed
Tighten Tighten to 20 Nm (15 lb ft).
Important Leave enough wire attached to the ECT sensor harness connector in order to create
manageable splices that are at least 40 mm (1.5 in) away from the other splice.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14489
20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit.
Cut off the ECT sensor harness connector and
wiring.
21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured
TO or WITHIN an existing protective conduit.
Note This step is to set up and verify the length of wiring that is required before cutting.
22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in
order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the
appropriate length.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splice or connector.
25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using
DuraSeal weatherproof splices. Refer to Splicing
Copper Wire Using Splice Sleeves in SI.
26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor
jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit
using tie straps.
Important You MUST run the engine at the specified RPM and until it reaches normal operating
temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool
down in order to top off the coolant level as needed.
28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan
tool to clear any DTCs.
Relocating the Engine Coolant Heater Cord
Important For reference, the procedure and graphics that are shown are from a Chevrolet
Silverado, but are similar for the other vehicles listed above.
1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit
from the engine compartment in order to determine the required extension
cord length.
3. Obtain an extension cord with the following features:
- 120 volt
- 14/3 gauge
- 15A capacity
- Three prong
- Polarized plug and receptacle
- Chemical resistant
- Grounded terminals
- Designed for use in a cold outdoor environment
- Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight
- Maximum length of 2.5-3 m (8-10 ft)
4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide
the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the
heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N
12345579 (in Canada, use P/N 10953481) or an equivalent.
6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14490
7. Wrap electrical tape around the connection as shown.
8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to
the engine coolant crossover pipe as shown.
9. Continue to route the extension cord to the exit location desired by the customer as shown.
10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch
any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the
extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the
engine coolant heater cord to the vehicle that were released to provide length.
Part Information
The extension cord may be obtained at any of the following outlets:
- Lowes*
- Home Depot*
- Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number:
CWRSJTOW3C14-10
USA: Cords should bear the UL symbol.
Canada: Cords should bear the ULc symbol or CSA approval.
*We believe these sources and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from these firms or for any
such items that may be available from other sources.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Shoe: > 10-06-04-008A > Jan > 11
> Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 14491
Warranty Information (excluding Saab Models)
For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > Page 14492
Parking Brake Shoe: Service and Repair
Parking Brake Shoe Replacement
Removal Procedure Caution: Refer to Brake Dust Caution . Caution: Refer to Brake Fluid Irritant
Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear tire
and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Relieve the park brake system tension at the equalizer assembly. 4. Remove the rear caliper
bracket. Refer to Rear Brake Caliper Bracket Replacement (See: Disc Brake System/Brake
Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement) .
5. Remove the rear rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and
Replacement/Rear Brake Rotor Replacement) .
6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. Refer to
Parking Brake Rear Cable Replacement (Z7U) (See:
Parking Brake Cable/Service and Repair/Parking Brake Rear Cable Replacement (Z7U)) .
7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the
rear wheel. 8. Remove the rear hub. Refer to Rear Wheel Bearing and Hub Replacement .
The rear hub, backing plate, park brake cable bracket, and park brake actuator will be removed as
an assembly.
9. Remove the 2 retainers (9) and the park brake cable bracket (8) from the park brake actuator
(4). Position the rear hub aside .
10. Remove the park brake shoe and actuator (4) from the backing plate (7).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Technical Service Bulletins > Page 14493
11. Separate the park brake shoe from the actuator.
Installation Procedure
1. Assemble the park brake shoe to the actuator (4). 2. Install the park brake shoe and actuator (4)
onto the backing plate (7). 3. Position the park brake shoe, actuator (4), and backing plate (7) over
the rear hub.
Notice: Refer to Fastener Notice .
4. Install the park brake cable bracket (8) and the 2 retainers (9).
Tighten the bracket retainers to 14 N.m (124 lb in).
5. Install the rear hub. Refer to Rear Wheel Bearing and Hub Replacement .
The rear hub, backing plate, park brake cable bracket, and park brake actuator will be installed as
an assembly.
6. Install and connect the rear park brake cable to the bracket at the rear wheel. 7. Connect the
park brake cable return spring to the park brake actuator and bracket at the rear wheel. 8. Install
the rear rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and
Replacement/Rear Brake Rotor Replacement) .
9. Install the rear caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (See: Disc
Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement) .
10. Install the rear tire and wheel assemblies . Refer to Tire and Wheel Removal and Installation .
11. Adjust the park brake system. Refer to Park Brake Adjustment (See: Adjustments) . 12. Lower
the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. Refer to
Front Carpet Retainer Replacement (Impala) . 3. Disconnect the electrical connector from the
switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1).
Installation Procedure
1. Install the parking brake indicator switch (1).
Notice: Refer to Fastener Notice .
2. Install the mounting screw.
Tighten the mounting screw to 3 N.m (26 lb in).
3. Connect the electrical connector to the switch.
Check the operation of the switch.
4. Install the left carpet retainers. Refer to Front Carpet Retainer Replacement (Impala) . 5. Install
the left side instrument panel insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Powertrain Component Views
Brake Booster Vacuum Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Powertrain Component Views > Page 14502
Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Rear of Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Powertrain Component Views > Page 14503
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 14504
Brake Booster Vacuum Sensor: Diagrams
Component Connector End Views
Brake Booster Vacuum Sensor (LZG, LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 14505
Brake Booster Vacuum Sensor: Service and Repair
Power Brake Booster Vacuum Sensor Replacement
Removal Procedure
1. Disconnect the brake booster vacuum sensor electrical connector.
2. Remove the brake booster vacuum sensor (1) from the booster. 3. Remove the brake booster
vacuum sensor grommet (2) from the booster.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 14506
1. Install the brake booster vacuum sensor grommet (2) to the booster. 2. Install the brake booster
vacuum sensor (1) to the booster.
3. Connect the brake booster vacuum sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair
Vacuum Brake Booster: Service and Repair
Power Vacuum Brake Booster Replacement (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Service and Repair
Vacuum Brake Booster Check Valve: Service and Repair
Vacuum Brake Booster Check Valve and/or Hose Replacement (5.3L)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic
Brake Control Module: > 09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: Customer Interest ABS/TCS - Stabiltrak Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 09-05-25-001 > Jun > 09 > ABS/TCS - Stabiltrak Message/DTC C0292
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Stabiltrak
Message/DTC C0292
TECHNICAL
Bulletin No.: 09-05-25-001
Date: June 02, 2009
Subject: Intermittent Service Stabilitrak Message After Key Cycle, DTC C0292 Set (Reprogram
Electronic Brake Control Module)
Models:
2008-2009 Chevrolet Impala
Condition
Some customers may comment that the Service Stabilitrak message is displayed intermittently
after the vehicle is first started. The Electronic Stability Control (ESC) Indicator and Traction
Control System (TCS) Warning lights may also come on the Instrument Panel Cluster (IPC)
intermittently. This may be the result of setting DTC C0292. The DTC will appear as a history code.
This condition can be very intermittent (every ten key cycles or more) and would occur before the
gear selector is taken out of Park.
Cause
The Service Stabilitrak message and the DTC is a result of the Electronic Brake Control Module
(EBCM) software not updated to the latest version.
Some additional key factors that trigger the occurrences of this condition and the EBCM DTC
C0292 include the following:
- Initial battery voltage is less than 11.8 volts going into CRANK mode.
- When starting the vehicle, the customer quickly enters CRANK and then releases to allow for the
starter relay control to take over engine start. This quick return to RUN allows the EBCM
diagnostics to start monitoring for diagnostic faults. In the case of DTC C0292 , the low voltage is
measured at the Yaw/Lateral Accelerometer sensor and the Service StabiliTrak message is then
displayed on the Driver Information Center (DIC).
Correction
Important The TECH 2(R) can provide some additional information or aid during diagnosis.
Using a TECH 2(R), interrogate the EBCM Freeze Frame Data or Additional DTC Information to
confirm the DTC SUB-CODE is 6A. If the DTC SUB-CODE is 6A, the revised EBCM software
calibration improvement will reduce the occurrence of the DTC C0292 diagnostic fault from setting.
Reprogram the EBCM with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the EBCM using the Service Programming System (SPS) with the latest software available on
TIS2WEB. Refer to Electronic Brake Control Module Programming and Setup procedures in SI. As
always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Powertrain Component Views
Electronic Brake Control Module: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Powertrain Component Views > Page 14529
Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 14530
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM) (without JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 14531
Electronic Brake Control Module (EBCM) (JL4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 14532
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Locations > Page 14533
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 14538
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views
Brake Booster Vacuum Sensor: Locations Powertrain Component Views
Powertrain Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF) Sensor/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum
Sensor (LZG/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views > Page 14543
Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Front of the Engine Compartment
LF of the Engine Compartment
1 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 2 - Brake Booster Vacuum Sensor
(LZ8/LS4) 3 - Windshield Wiper Motor 4 - Electronic Brake Control Module (EBCM) 5 - A/C
Refrigerant Pressure Sensor 6 - Transmission Control Module (TCM) 7 - Engine Control Module
(ECM) 8 - G101 9 - Inflatable Restraint Front End Sensor - Left
Left Rear of Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Powertrain Component Views > Page 14544
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 14545
Brake Booster Vacuum Sensor: Diagrams
Component Connector End Views
Brake Booster Vacuum Sensor (LZG, LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 14546
Brake Booster Vacuum Sensor: Service and Repair
Power Brake Booster Vacuum Sensor Replacement
Removal Procedure
1. Disconnect the brake booster vacuum sensor electrical connector.
2. Remove the brake booster vacuum sensor (1) from the booster. 3. Remove the brake booster
vacuum sensor grommet (2) from the booster.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 14547
1. Install the brake booster vacuum sensor grommet (2) to the booster. 2. Install the brake booster
vacuum sensor (1) to the booster.
3. Connect the brake booster vacuum sensor electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Powertrain Component Views
Brake Fluid Level Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Powertrain Component Views > Page 14552
Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component
Views
Front of Vehicle/Engine Compartment Component Views
Left Rear of Engine Compartment
1 - Brake Booster Vacuum Sensor (LZG/LS4) 2 - Brake Booster 3 - Brake Fluid Level Switch
Right Front of the Engine Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Powertrain Component Views > Page 14553
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 14554
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 14555
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Disconnect the electrical connector from brake fluid level sensor.
2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining
tabs on the end of the brake fluid level sensor (1) and
press the sensor through the reservoir to remove.
Installation Procedure
1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor
retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations
Parking Brake Release Switch: Locations
Instrument Panel/Center Console Component Views
Pedal Assemblies
1 - Park Brake Switch 2 - Dash Panel 3 - Brake Pedal Position Sensor 4 - Accelerator Pedal
Position (APP) Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Page 14559
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. Refer to
Front Carpet Retainer Replacement (Impala) . 3. Disconnect the electrical connector from the
switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1).
Installation Procedure
1. Install the parking brake indicator switch (1).
Notice: Refer to Fastener Notice .
2. Install the mounting screw.
Tighten the mounting screw to 3 N.m (26 lb in).
3. Connect the electrical connector to the switch.
Check the operation of the switch.
4. Install the left carpet retainers. Refer to Front Carpet Retainer Replacement (Impala) . 5. Install
the left side instrument panel insulator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Service and Repair
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-05-25-004A > Oct >
08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: Customer Interest ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052
Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-05-25-004A > Oct >
08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 14574
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set
Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - ABS/TCS Lamps ON/DTC's
C0035-C0052 Set
TECHNICAL
Bulletin No.: 08-05-25-004A
Date: October 27, 2008
Subject: Antilock Brake System (ABS), Traction Control System (TCS) or StabiliTrak(R) Light On,
DTCs C0035-C0052 Set (Perform Diagnostic Component Test Procedure and Repair as
Necessary)
Models: 2007 Buick Terraza 2007-2009 Buick Allure, LaCrosse, Lucerne 2007-2008 Cadillac XLR
2007-2009 Cadillac DTS, SRX, and STS 2007-2008 Chevrolet Corvette 2007-2009 Chevrolet
Impala, Uplander 2007-2008 Pontiac Grand Prix 2007-2009 Pontiac Montana SV6 2007 Saturn
Relay
Supercede:
This bulletin is being updated to add models. Please discard Corporate Bulletin Number
08-05-25-004 (Section 05 - Brakes).
Condition
Some customers may comment that the Antilock Brake System (ABS), Traction Control System
(TCS) or StabiliTrak(R) (if equipped) warning lights are illuminated. Upon investigation, one or
more of the following DTCs may be in history or current.
Correction
Begin diagnostics with the component test procedure listed below. If the cause is not found,
proceed to the Circuit/System Testing on the applicable Diagnostic Information and Procedures
document for the vehicle you are working on. SI Diagnostic Information and Procedures are being
revised to reflect this change in strategy.
1. With the ignition OFF, disconnect the harness connector at the appropriate wheel speed sensor.
2. Test for 850-1350 ohms between the signal terminal A and the low reference signal terminal B.
During the test, check for an intermittent circuit condition by gently moving the wheel speed sensor
pigtail harness. If not within the specified range, replace the wheel speed sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
08-05-25-004A > Oct > 08 > ABS/TCS - ABS/TCS Lamps ON/DTC's C0035-C0052 Set > Page 14580
3. Test for infinite resistance between each terminal and the steering knuckle. Reverse the test
leads, test for infinite resistance between each terminal and the steering knuckle again. If less than
the specified value, replace the appropriate wheel speed sensor.
4. Spin the wheel while monitoring the voltage between the signal terminal A and the low reference
terminal B. The voltage should be greater than 100 mV AC. If less than the specified range, replace
the wheel speed sensor.
Warranty Information
For vehicles repaired under warranty, use the applicable bearing and hub assembly published
labor code.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 11-03-08-001 > Apr > 11 > Steering - Growl Type Noise Coming from Front of Vehicle
Axle Nut: All Technical Service Bulletins Steering - Growl Type Noise Coming from Front of Vehicle
TECHNICAL
Bulletin No.: 11-03-08-001
Date: April 14, 2011
Subject: Growl Type Noise Coming from Front of Vehicle
Models:
2006-2011 Chevrolet Impala (Including Police Vehicles)
Condition
Some customers may comment on a growl type noise coming from the front of the vehicle at
speeds between 32 and 80 km/h (20 and 50 mph).
Cause
This condition may be caused by loss of preload on the front wheel bearings.
Correction
Important DO NOT replace the front wheel bearing and hub for this condition.
To diagnose the noise, retorque the existing front axle shaft nut to 220 Nm (162 lb ft) and test drive
the vehicle. If the noise is eliminated, replace both front axle shaft nuts with GM P/N 10257766 and
tighten to the specification indicated below. On vehicles equipped with the police package (RPOs
9C1 or 9C3), add an additional Nord-Lock washer, GM P/N 20861489 between the hub and nut as
shown in the illustration below.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 11-03-08-001 > Apr > 11 > Steering - Growl Type Noise Coming from Front of Vehicle > Page 14586
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed
Sensor: > 11-03-08-001 > Apr > 11 > Steering - Growl Type Noise Coming from Front of Vehicle > Page 14592
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 14593
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Right Rear Wheel Speed Sensor (Left Similar)
1 - Wheel Speed Sensor (WSS) - Right Rear (Wheel Speed Sensor (WSS) - Left Rear Similar)
Right Front Wheel Speed Sensor (Left Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 14594
1 - Wheel Speed Sensor (WSS) Connector - Right Front (Wheel Speed Sensor (WSS) Connector Left Front Similar) 2 - Wheel Speed Sensor (WSS) - Right Front (Wheel Speed Sensor (WSS) Left Front Similar)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 14595
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor (WSS) - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Left Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 14596
Wheel Speed Sensor (WSS) - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor (WSS) - Right Rear
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 14597
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Service and Repair > Procedures
Yaw Rate Sensor: Procedures
Yaw Rate Reference Table Resetting
Circuit Description
Optimum vehicle stability enhancement system (VSES) function is dependant on many variables.
The characteristics of a specific vehicle, that affect vehicle handling or input signals to the
electronic brake control module (EBCM), ultimately determine how the VSES operates. The basic
EBCM software must be fine tuned as the vehicle is operated. This logic is referred to as adaptive
learning.
Adaptive learning is accomplished by maintaining a yaw rate sensor/lateral accelerometer data
table in the EBCM memory. As the vehicle is operated, the table is populated with data that is later
referenced, and sometimes modified, to allow the EBCM to provide the best possible stability
control for the specific vehicle.
Important: If the data in the yaw rate sensor/lateral accelerometer data table becomes unreliable,
false activations of the VSES, poor VSES performance or false setting of DTC C0186 or C0196
may result.
A replacement EBCM may have some unreliable data stored in the yaw rate sensor/lateral
accelerometer data table. For this reason, it is important to perform the yaw rate reference table
reset procedure after replacing the EBCM.
Replacement of the yaw rate sensor/lateral accelerometer or the installation of different size tires
may also the data stored in the table to become unreliable. Therefore, the yaw rate reference table
reset procedure must be performed.
This procedure is to be used only for vehicles equipped with VSES (JL4).
1. Turn OFF the ignition. 2. Disconnect the yaw rate sensor/lateral accelerometer harness
connector. 3. Start the engine. 4. Apply firm and steady pressure to the brake pedal for at least 10
seconds. 5. Turn OFF the ignition. 6. Reconnect the yaw rate sensor/lateral accelerometer harness
connector. 7. Turn ON the ignition and use the scan tool to clear the DTCs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Service and Repair > Procedures > Page 14602
Yaw Rate Sensor: Removal and Replacement
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Remove the front floor center console. Refer to Front Floor Console
Replacement (Impala) .
3. Remove the 2 yaw rate sensor/lateral accelerometer mounting nuts (2).
4. Disconnect the yaw rate sensor/lateral accelerometer electrical connector (2). 5. Remove the
yaw rate sensor/lateral accelerometer (1).
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Service and Repair > Procedures > Page 14603
1. Install the yaw rate sensor/lateral accelerometer (1) .
Notice: Refer to Fastener Notice .
2. Install the 2 yaw rate sensor/lateral accelerometer nuts (2).
Tighten the nuts to 6 N.m (53 lb in).
3. Connect the yaw rate sensor/lateral accelerometer electrical connector (2). 4. Install the front
floor center console. Refer to Front Floor Console Replacement (Impala) . 5. Install a scan tool. 6.
Using the special functions menu on the scan tool, reset the yaw rate sensor. 7. Perform the
Diagnostic System Check - Vehicle .
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Powertrain Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Powertrain Component Views > Page 14610
Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 14611
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 14612
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 14613
Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Locations > Page 14618
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14621
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14622
are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14623
Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14624
cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14625
22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14626
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14627
7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14628
3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 14629
7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection
Battery Cable: Service and Repair Battery Negative Cable Disconnection and Connection
Battery Negative Cable Disconnection and Connection (RPO LS4)
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
Caution: Refer to Battery Disconnect Caution.
1. Record all of the vehicle's preset radio stations. 2. Turn OFF all lamps and accessories. 3. Turn
the ignition switch to the OFF position. 4. Loosen the negative battery cable terminal nut. 5.
Remove the negative battery cable terminal (3) from the battery.
Installation Procedure
Important: Clean any existing oxidation from the contact face of the battery terminal and battery
cable using a wire brush before installing the battery cable to the battery terminal.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14639
1. Install the negative battery cable terminal (2) to the battery.
Notice: Refer to Fastener Notice.
2. Tighten the negative battery cable terminal nut.
Tighten the nut to 15 N.m (11 lb ft).
3. Set the clock and program the radio stations back into the radio as recorded at the beginning of
the procedure. Refer to Radio/Audio System
Description and Operation.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14640
Battery Cable: Service and Repair Battery Positive and Negative Cable Replacement
Battery Positive and Negative Cable Replacement (RPO LS4)
Removal Procedure
Important: When replacing battery cables be sure to use replacement cables that are the same
type, gage, and length.
1. Disconnect the negative battery cable (3). 2. Open the positive battery cable terminal lead cover
(1). 3. Loosen the positive battery cable terminal lead nut 4. Remove the positive battery cable
terminal from the battery. 5. Disconnect the instrument panel (I/P) harness electrical connector (2)
from the battery current sensor.
6. Disconnect the battery cable connector from the I/P harness electrical connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14641
7. Remove the bussed electrical center (BEC) cover. 8. Remove the positive battery cable junction
block lead nut (1). 9. Remove the positive battery cable terminal (2) from the BEC.
10. Remove the ground wire bolt (1) and reposition the wire (5) from the top rail. 11. Remove the
battery cable harness retaining clips (2, 3, and 4) from the front rail and fan shroud. 12. Raise and
support the vehicle. Refer to Vehicle Lifting.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14642
13. Remove the battery cable harness retainers from the engine cradle.
14. Remove the transaxle stud nut (8). 15. Remove the battery cable ground (7) from the transaxle
stud. 16. Reposition the positive battery cable boot (4) at the starter solenoid. 17. Remove the
starter solenoid BAT terminal nut (3) from the starter. 18. Remove the positive battery cable (2)
from the starter motor. 19. Remove the positive battery cable clip (5) from the transmission stud.
20. Lower the vehicle. 21. Remove the positive and negative battery cable from the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14643
22. If replacing the positive and negative battery cable, perform the following:
1. Cut the tie straps and electrical tape attaching the battery current sensor to the battery cable. 2.
Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
3. Slide the battery current sensor (1) off of the battery cable.
Installation Procedure
1. If the positive and negative battery cable was replaced, perform the following:
1. Slide the battery current sensor (1) onto the battery cable.
Important: Ensure that the tape tab is pointing away from the negative cable terminal.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14644
2. Using NEW tie straps and electrical tape, attach the battery current sensor to the battery cable.
2. Install the positive and negative battery cable to the vehicle. 3. Raise and support the vehicle. 4.
Install the positive battery cable (2) to the starter motor.
Notice: Refer to Fastener Notice.
5. Install the starter solenoid BAT terminal nut (3) to the starter.
Tighten the nut to 10 N.m (89 lb in).
6. Position the positive battery cable boot (4) at the starter solenoid. 7. Install the positive battery
cable clip (5) to the transmission stud. 8. Install the battery cable ground (7) to the transaxle stud.
9. Install the transaxle stud nut (8).
Tighten the nut to 30 N.m (22 lb ft).
10. Install the battery cable harness retainers from the engine cradle. 11. Lower the vehicle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14645
12. Position the ground wire (5) and install the ground wire bolt (1) to the top rail.
Tighten the nut to 10 N.m (89 lb in).
13. Install the battery cable harness retaining clips (2, 3, and 4) to the front rail and fan shroud.
14. Install the positive battery cable terminal (2) to the BEC. 15. Install the positive battery cable
junction block lead nut (1).
Tighten the nut to 10 N.m (89 lb in).
16. Install the BEC cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and
Repair > Battery Negative Cable Disconnection and Connection > Page 14646
17. Connect the battery cable connector to the I/P harness electrical connector.
18. Connect the I/P harness electrical connector (2) to the battery current sensor. 19. Install the
positive battery cable terminal to the battery. 20. Tighten the positive battery cable terminal lead
nut.
Tighten the nut to 15 N.m (11 lb ft).
21. Snap closed the positive battery cable terminal lead cover (1). 22. Connect the negative battery
cable (3).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Powertrain Component Views
Battery Current Sensor: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Powertrain Component Views > Page 14651
Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 14652
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 14653
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement (RPO LS4)
Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (2) from the battery current
sensor. 2. Remove the positive and negative battery cable.
3. Cut the tie straps and electrical tape attaching the battery current sensor to the positive battery
cable. 4. Squeeze the battery cable branches together.
Important: Note the position of the battery current sensor prior to removal.
5. Slide the battery current sensor (1) off of the battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 14654
Installation Procedure
Important: Ensure that the tape tab is pointing away from the battery prior to installation.
1. Slide the NEW battery current sensor (1) up onto the battery cable. 2. Using NEW tie straps and
electrical tape, attach the battery current sensor to the positive battery cable.
3. Install the positive and negative battery cable. 4. Connect the I/P harness electrical connector (2)
to the battery current sensor.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair
Battery Tray: Service and Repair
Battery Tray Replacement (LS4)
Removal Procedure
1. Remove the battery. 2. Remove the battery tray bolts. 3. Remove the battery tray.
Installation Procedure
1. Install the battery tray.
Notice: Refer to Fastener Notice.
2. Install the battery tray bolts.
Tighten the bolts to 5 N.m (44 lb in).
3. Install the battery.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications
Alternator: Specifications
Generator Usage
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 14662
Alternator: Diagrams
Component Connector End Views
Generator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement (LS4)
Alternator: Service and Repair Generator Bracket Replacement (LS4)
Generator Bracket Replacement (LS4)
Removal Procedure
1. Remove the generator. 2. Remove the idle pulley. 3. Raise and support the vehicle. Refer to
Vehicle Lifting. 4. Remove the lower tensioner bolt and rotate the tensioner to access the generator
bracket bolt. 5. Lower the vehicle. 6. Remove the generator bracket bolts. 7. Remove the generator
bracket from the stud.
Installation Procedure
1. Install the generator bracket to the stud.
Notice: Refer to Fastener Notice.
2. Install the generator bracket bolts.
Tighten the bolts to 50 N.m (37 lb ft).
3. Raise the vehicle. 4. Install the lower generator bracket bolt.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement (LS4) > Page 14665
Tighten the bolt to 50 N.m (37 lb ft).
5. Install the lower tensioner bolt.
Tighten the bolt to 50 N.m (37 lb ft).
6. Lower the vehicle. 7. Install the idler pulley. 8. Install the generator.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement (LS4) > Page 14666
Alternator: Service and Repair Generator Replacement (LS4)
Generator Replacement (LS4)
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the engine sight shield. 3. Remove the drive
belt. 4. Disconnect the generator electrical connector (2). 5. Position aside the protective boot (1)
from the generator output BAT terminal for access. 6. Remove the generator output BAT terminal
nut (4) and remove the positive battery lead (3) from the generator.
7. Remove the generator bolts and generator.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket Replacement (LS4) > Page 14667
Notice: Refer to Fastener Notice.
1. Install the generator and bolts.
Tighten the bolts to 50 N.m (37 lb ft).
2. Install the positive battery lead (3) and generator output BAT terminal nut (4) to the generator.
Tighten the nut to 20 N.m (15 lb ft).
3. Position the protective boot (1) to the generator output BAT terminal. 4. Connect the generator
electrical connector (2). 5. Install the drive belt. 6. Install the engine sight shield. 7. Connect the
negative battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Locations
Ignition Switch Lock Cylinder: Locations
Instrument Panel/Center Console Component Views
Left Front of the Passenger Compartment, in the Steering Column
1 - Ignition Switch 2 - Theft Deterrent Module (TDM) 3 - Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Locations > Page 14673
Ignition Switch Lock Cylinder: Diagrams
Component Connector End Views - Continued
Ignition Lock Cylinder Control Actuator
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Special Tools
BO-48370 Lock Cylinder Cap Installer
Ignition Lock Cylinder
The column-mount ignition lock cylinder uses 7 of the 10 key cut positions, 1, 2, and 4 through 8,
when counting from the key head. The tumbler orientations alternate in adjacent locations from
side to side with 4 on one side and 3 on the other.
Important: The ignition lock cylinder tumblers (3) are not self-retaining and must be held in place if
the key in not fully inserted into the lock cylinder or until the tumbler retainers (4) are properly
staked into the cylinder.
1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing
upward, spring-loaded retainer facing downward. 2. Insert one tumbler spring (2) each into the 3
tumbler spring holes. 3. The first tumbler to be loaded will be key cut position number 1, the first
number in the key code. Determine the cut depth at this position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly
(1), the end where the key is inserted. It may be necessary to move the sidebar (5), already
pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the
correct tumbler slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2
remaining tumblers (3) into the tumbler slots located at
key cut positions 5 and 7.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retention lug is facing downward,
spring-loaded retainer facing upward, and then remove
the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14676
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 2. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 4, 6, and 8.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder assembly (1). The sidebar
(5) should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. With the matching
key fully inserted into the cylinder assembly (1), install and stake one tumbler retainer (4) into the
recessed area on the cylinder.
Be careful not to damage the cylinder assembly in any way while staking the tumbler retainer.
13. Rotate the cylinder assembly (1) to the opposite side and repeat the procedure defined in the
previous step.
Front Side Door Lock Cylinder
The front side door lock cylinder uses 8 of the 10 key cut positions, 3 through 10 when counting
from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4
on each side.
Important: The front side door lock cylinder tumblers (3) are not self-retaining and must be held in
place if the key in not fully inserted into the lock cylinder or until the cylinder (1) is assembled into
the case assembly (4). Left side shown, right side opposite.
1. Hold the uncoded cylinder (1) positioned so the side with the rotational stop lug is facing upward,
as shown. 2. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler
to be loaded will be key cut position 3, the third number in the key code. Determine the cut depth at
this position and install the
corresponding tumbler (3) into the tumbler slot nearest the front of the lock cylinder assembly (1),
the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check the correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so the side with the rotational stop lug is facing downward and then
remove the matching key. Remember the tumblers (3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14677
are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate the tumbler (3) surfaces using the lubrication provided. 12. Hold the case
assembly (4), left side shown, right side opposite, with the pre-staked detent spring retainer facing
downward. 13. First insert one detent spring (5) and then one detent ball (6) into the detent spring
hole located to the rear and inside of the cylinder case assembly
(4). The detent spring and detent ball are not self-retaining and must be held in place until the
coded cylinder is installed into the case assembly.
Caution: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the
case assembly (4). Make sure the detent spring (5)
and detent ball (6) are held in place until the coded cylinder is fully installed. The detent ball should
line up with the V-shaped groove on the rear of the cylinder, which will prevent the detent spring
and detent ball from falling out of the case assembly.
15. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the
case assembly (4). 16. Insert one shutter spring (7) each into the two shutter spring holes located
on the front face of the cylinder (1). 17. Install the shutter assembly (8) into the recessed area on
the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
18. Install the lock cylinder cap (9) by aligning the drain hole in the cap with the bottom of the case
assembly (4). Snap the cap into place with light
hand pressure. Be sure the cap is securely retained on the case assembly. Also, be sure that the
shutter springs (7) push the shutter assembly (8) up against the inside surface of the cap.
19. Install the lever (10), left side shown, right side opposite, onto the end of the cylinder (1). 20.
Install the retaining ring (11) in the groove at the end of the cylinder (1) to secure the lever (10) to
the cylinder.
Rear Compartment Lid Lock Cylinder - Police Vehicles 9C1 and 9C3
The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from
the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on
each side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14678
Important: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be
held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is
assembled into the case (4).
1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward. 2.
Insert one tumbler spring (2) each into the 4 tumbler spring holes. 3. The first tumbler to be loaded
will be key cut position number 3, the third number in the key code. Determine the cut depth at this
position and
install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the
end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers (3) into the tumbler slots located at
key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the
matching key. Remember the tumblers (3) are not
self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes. 8. The first tumbler to be
loaded will be key cut position number 4. Determine the cut depth at this position and install the
corresponding tumbler (3)
into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3
remaining tumblers into the tumbler slots located at key
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14679
cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching
key into the cylinder (1). All tumblers should be
flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided. 12. With the matching key
fully inserted into the coded cylinder, install the coded cylinder into the case (4). 13. Remove the
matching key being careful to keep the coded cylinder (1) fully inserted into the case (4). 14. Insert
one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder
(1). 15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1).
Be sure that the ends of the pin on the shutter assembly
are positioned in the pin cavities located in the front face of the cylinder.
Important: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock
cylinder in any way while staking the cap.
16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370.
Ensure proper orientation and set the cylinder
assembly (14), (which includes the case (4), coded cylinder (1), shutter springs (5), and shutter
assembly (6)) and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris
and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the
staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to
the cylinder assembly (14). Repeat previous step until cap is securely staked to the cylinder
assembly. Remove assembly from the staking cup (15). If necessary, insert the removal punch (17)
into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs (5) push
the shutter assembly (6) up against the inside surface of the cap (7).
17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case
(4) until it seats behind the cap (7). 18. Install the return spring (9) over the back end of the cylinder
(1) with the straight hook facing the rear of the case (4). Engage the straight hook of
the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1). 20. Install the retaining
ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage
the bent hook of the return
spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs
onto the case (4). Be sure the theft deterrent switch is
engaged with the end of the cylinder and is securely attached to the case.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14680
22. Check the operation of the lock assembly. The return spring (9) should provide a
counterclockwise snap back.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14681
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Removal Procedure
Caution: Refer to Restraint System Service Precautions.
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the ignition lock
cylinder. 3. Remove the ignition switch. 4. Remove the steering column tilt head components. 5.
Remove the turn signal switch housing. 6. Remove the turn signal and multifunction switch
assembly only.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14682
7. Remove the park lock cable assembly (1) from the ignition lock cylinder case in the following
way:
1. Use a small blade to push against the locking tab on the end of the park lock cable assembly (1).
2. Disconnect the park lock cable assembly (1) from the ignition lock cylinder case.
8. Remove the 3 TORX(R) screws (2) from the ignition lock cylinder case (1). 9. Remove the
ignition lock cylinder case (1) from the steering column tilt head assembly.
Installation Procedure
1. Align the ignition lock cylinder case (1) with the steering column tilt head assembly.
Notice: Refer to Fastener Notice.
2. Screw the 3 TORX(R) screws (2) into the ignition lock cylinder case (1).
Tighten the 3 TORX(R) screws to 7 N.m (62 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14683
3. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the ignition
lock cylinder case.
Important: Press the turn signal switch housing firmly against the steering column tilt head in order
for the screws from the turn signal and multifunction switch assembly to align.
4. Install the turn signal switch housing. 5. Install the turn signal and multifunction switch assembly
only. 6. Install the steering column tilt head components.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 14684
7. Install the ignition switch only. 8. Install the ignition lock cylinder. 9. Enable the SIR system.
Refer to SIR Disabling and Enabling.
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information
Key: Technical Service Bulletins Locks - Key Code Security Rules and Information
INFORMATION
Bulletin No.: 10-00-89-010
Date: May 27, 2010
Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada
Only)
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior
Saturn and Saab 2002 and Prior Isuzu
Attention:
This bulletin has been created to address potential issues and questions regarding KeyCode
security. This bulletin should be read by all parties involved in KeyCode activity, including dealer
operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin
should be printed and maintained in the parts department for use as a reference.
Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009.
Where Are Key Codes Located?
General Motors provides access to KeyCodes through three sources when a vehicle is delivered to
a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a
small white bar coded tag sent with most new vehicles that also has the key code printed on it.
Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed
on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code
Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers.
The third source for Key codes is through the GM KeyCode Look-Up feature within the
OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model
years from the current model year.
When a vehicle is received by the dealership, care should be taken to safeguard the original
vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have
access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been
completed, the KeyCode information belongs to the customer and General Motors.
Tip
Only the original invoice contains key code information, a re-printed invoice does not.
GM KeyCode Look-Up Application for GM of Canada Dealers
All dealers should review the General Motors of Canada KeyCode Look-Up Policies and
Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates &
keys").
Please note that the KeyCode Access site is restricted. Only authorized users should be using this
application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently
goes back 17 years from current model year.
Important notes about security:
- Users may not access the system from multiple computers simultaneously.
- Users may only request one KeyCode at a time.
- KeyCode information will only be available on the screen for 2 minutes.
- Each user is personally responsible for maintaining and protecting their password.
- Never share your password with others.
- User Id's are suspended after 6 consecutive failed attempts.
- User Id's are disabled if not used for 90 days.
- Processes must be in place for regular dealership reviews.
- The Parts Manager (or assigned management) must have processes in place for employee
termination or life change events. Upon termination individuals access must be turned off
immediately and access should be re-evaluated upon any position changes within the dealership.
- If you think your password or ID security has been breached, contact Dealer Systems Support at
1-800-265-0573.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 14689
Each user will be required to accept the following agreement each time the KeyCode application is
used.
Key Code User Agreement
- Key codes are proprietary information belonging to General Motors Corporation and to the vehicle
owner.
- Unauthorized access to, or use of, key code information is unlawful and may subject the user to
criminal and civil penalties.
- This information should be treated as strictly confidential and should not be disclosed to anyone
unless authorized.
I will ensure that the following information is obtained prior to releasing any Key Code information:
1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership.
Registration should have normal markings from the Province that issued the registration and
possibly the
receipt for payment recorded as well.
Important
- GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving
out key codes.
- When the ownership of the vehicle is in doubt, dealership personnel should not provide the
information.
Key code requests should never be received via a fax or the internet and key codes should never
be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the
expected manner that dealers will use to release a key code or as otherwise stipulated in this
bulletin or other materials.
- Key codes should NEVER be sent via a fax or the internet.
- Each Dealership should create a permanent file to document all KeyCode Look Up transactions.
Requests should be filed by VIN and in each folder retain copies of the following:
- Government issued picture ID (Drivers License)
- Registration or other proof of ownership.
- Copy of the paid customer receipt which has the name of the employee who cut and sold the key
to the customer.
- Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up
to either GM or law enforcement officials.
- Dealership Management has the ability to review all KeyCode Look-Up transactions.
- Dealership KeyCode documentation must be retained for two years.
Frequently Asked Questions (FAQs) for GM of Canada Dealers
How do I request a KeyCode for customer owned vehicle that is not registered?
Scrapped, salvaged or stored vehicles that do not have a current registration should still have the
ownership verified by requesting the vehicle title, current insurance policy and / or current lien
holder information from the customers financing source. If you cannot determine if the customer is
the owner of the vehicle, do not provide the key code information. In these cases, a short
description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on
file. Any clarifying explanation should be entered into the comments field.
How do I document a KeyCode request for a vehicle that is being repossessed?
The repossessor must document ownership of the vehicle by providing a court ordered
repossession order and lien-holder documents prior to providing key code information. Copies of
the repossessors Drivers License and a business card should be retained by the dealership for
documentation.
What do I do if the registration information is locked in the vehicle?
Every effort should be made to obtain complete information for each request. Each Dealership will
have to decide on a case by case basis if enough information is available to verify the customer's
ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and
or current lien information from the customers financing source. Dealership Management must be
involved in any request without complete information. If you cannot determine if the customer is the
owner of the vehicle, do not provide the key code information.
Can I get a print out of the information on the screen?
It is important to note that the Key Code Look Up Search Results contain sensitive and/or
proprietary information. For this reason GM recommends against printing it. If the Search Results
must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper
or illegal use.
Who in the dealership has access to the KeyCode application?
Dealership Parts Manager (or assigned management) will determine, and control, who is
authorized to access the KeyCode Look Up application. However, we anticipate that dealership
parts and service management will be the primary users of the application. The KeyCode Look Up
application automatically tracks each user activity session. Information tracked by the system
includes: User name, User ID, all other entered data and the date/time of access.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 14690
What if I input the VIN incorrectly?
If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN
or that the VIN has been entered incorrectly) the system will return an error message.
If I am an authorized user for the KeyCode application, can I access the application from home?
Yes.
What if I suspect key code misuse?
Your dealership should communicate the proper procedures for requesting key codes. Any
suspicious activity either within the dealership or externally should be reported to Dealer Systems
Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
Whose key codes can I access through the system?
At this time the following Canadian vehicle codes are available through the system: Chevrolet,
Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu
(up to 2002 model year) for a maximum of 17 model years.
What should I do if I enter a valid VIN and the system does not produce any key code information?
Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This
may be the result of new vehicle information not yet available. In addition, older vehicle information
may have been sent to an archive status. If you do not receive a key code returned for valid VIN,
you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
How do I access KeyCodes if the KeyCode Look-up system is down?
If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling
dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have
the customer contact Roadside assistance, OnStar if subscribed, or 911.
What should I do if the KeyCode from the look-up system does not work on the vehicle?
On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In
cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting
equipment that the key has been cut correctly. If the key has been cut correctly you may be able to
verify the proper KeyCode was given through the original selling dealer. When unable to verify the
KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock
cylinder may have been changed. In these situations following the proper SI document for recoding
a key or replacing the lock cylinder may be necessary.
How long do I have to keep KeyCode Records?
Dealership KeyCode documentation must be retained for two years.
Can I get a KeyCode changed in the Look-Up system?
Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed.
Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
What information do I need before I can provide a driver of a company fleet vehicle Keys or
KeyCode information?
The dealership should have a copy of the individual's driver's license, proof of employment and
registration. If there is any question as to the customer's employment by the fleet company, the
dealer should attempt to contact the fleet company for verification. If there is not enough
information to determine ownership and employment, this information should not be provided.
How do I document a request from an Independent Repair facility for a KeyCode or Key?
The independent must provide a copy of their driver's license, proof of employment and signed
copy of the repair order for that repair facility. The repair order must include customer's name,
address, VIN, city, province and license plate number. Copies of this information must be included
in your dealer KeyCode file.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 14691
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip
Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter
Diagnostic Tip
INFORMATION
Bulletin No.: 09-08-52-004A
Date: January 08, 2010
Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter
When Transmitter Battery is Weak or Dead
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade
ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR,
Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra,
Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn
AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories).
Follow these procedures if a customer comments that their GM Accessory 2-way transmitter
stopped communicating with the vehicle.
About GM Accessory 2-Way Remote Start
The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a
2-way advanced remote start system, but often the 2-way transmitter may only be coded to one
vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter
will enter second vehicle mode and will not control the original vehicle until a subsequent double
press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of
the 2-way transmitter should be thought of as an individual transmitter with its own unique code.
Test the Transmitter Battery
Note
This test should be performed prior to releasing the vehicle or transmitter to the customer.
All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or
replacement of a transmitter battery using the following procedure.
1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of
the unlock button, observe the battery gauge located in the upper right corner of the LCD display.
The gauge should read
full (three bars inside the battery icon).
If after having a new battery installed, the battery goes dead within five months, the transmitter
could have high sleep current, causing the battery to go dead. Replace the transmitter.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition
exhibited is resolved without completing every step, the remaining steps do not need to be
performed.
Determine if Transmitter is in Second Vehicle Mode
1. Press and release any of the face buttons on the 2-way transmitter and observe the display on
power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be
displayed on the left side of the transmitter display. Is the 2-way
transmitter in second vehicle mode?
If Yes, the 2-way transmitter is working properly.
- Press and release the left side button twice within one second. The 2-way transmitter should exit
second vehicle mode.
- Press and release the lock button. Press and release the unlock button.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 14697
- Confirm that the vehicle responds with the appropriate lock and unlock function.
- If Yes , the 2-way transmitter was in mode B.
- Press and release the left side button twice within one second. The 2-way transmitter should
enter second vehicle mode.
- Use the "next available slot" method in the scan tool to program the 2-way transmitter to the
2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI.
- Both vehicle modes of the 2-way transmitter should now be coded to the vehicle.
If No:
The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal
diagnostic procedures.
Parts Information
For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts
Catalog or Corporate Bulletin Number 09-00-89-025A.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 14698
Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote
Start
INFORMATION
Bulletin No.: 09-00-89-025A
Date: October 26, 2009
Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT
2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche,
Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse
2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent
2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA,
OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY
Attention:
This bulletin does not apply to GMODC dealers.
Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin
Number 09-00-89-025 (Section 00 - General Information).
This bulletin is being published to provide information on locating service part numbers for GM
Accessory, 2-Way Advanced Remote Start Systems.
Dealers should consult the chart below and use the correct service part. Dealers should not use
entire kit for warranty or repair work.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 14699
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 14700
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 14701
Parts Information
Service parts common to all 2-Way Advanced Remote Start Systems
Transmitter Battery 12493150
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Diagrams
Starter Motor: Diagrams
Component Connector End Views - Continued
Starter
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Starter Motor: Service and Repair
Starter Motor Replacement (LS4)
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the starter solenoid BAT terminal nut (3) and
remove the positive battery cable (2) from the starter motor. 3. Remove the engine harness
terminal (4) from the starter motor.
4. Disconnect the starter motor electrical connector (1). 5. Remove the air cleaner assembly.
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6. Remove the starter motor bolts and starter motor.
Installation Procedure
1. Position the starter motor to the engine.
Notice: Refer to Fastener Notice.
2. Install the starter bolts.
Tighten the bolts to 50 N.m (37 lb ft).
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3. Connect the starter motor electrical connector (1).
4. Install the engine harness terminal (4) to the starter motor. 5. Install the positive battery cable (2)
and the starter solenoid BAT terminal nut (3) to the starter motor.
Tighten the solenoid BAT terminal nut to 10 N.m (89 lb in).
6. Install the air cleaner assembly. 7. Connect the negative battery cable.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information >
Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Locations
Starter Solenoid: Locations
Powertrain Component Views
Front of the Engine (LS4)
1 - G111 2 - Starter Solenoid 3 - X100 4 - Starter 5 - Cable Pro fuse 6 - G113
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Accessory Relay > Component
Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 14784
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 14791
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14838
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14839
and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14840
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14841
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14842
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 14843
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14844
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14845
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14846
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14847
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14848
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14849
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Accessory Power Outlet - Center Console 1 (with Floor Console)
Accessory Power Outlet - Center Console 2 (with Floor Console)
Accessory Power Outlet - Center Console Compartment (with Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14850
Accessory Power Outlet - Center Seat (without Floor Console)
Accessory Power Outlet - I/P 1 (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 14851
Accessory Power Outlet - I/P 2 (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Page 14852
Auxiliary Power Outlet: Service and Repair
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigar Lighter Socket Remover
Removal Procedure
1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle:
1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the
front of the receptacle. The J 42059 pushes the
plastic latches from these tab windows and the receptacle can be pulled straight out.
2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit
straight into the receptacle. Angle the J 42059
slightly for insertion into the receptacle.
3. Insert the other side of the "T" into the opposite tab window.
You must move the J 42059 handle toward horizontal to engage the other tab window.
4. Use the J 42059 to pull the receptacle straight out.
3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate
method:
1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in
the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Page 14853
1. Route the connector through the retainer. Align the accessory power receptacle retainer to the
slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the
electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer.
Install the accessory power receptacle by pressing into place until fully seated. 5. Install the
accessory power receptacle fuse.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Page 14854
Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Branching Point > Component
Information > Diagrams > JX205
Branching Point: Diagrams JX205
Splice Pack Connector End Views
JX205
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Branching Point > Component
Information > Diagrams > JX205 > Page 14859
Branching Point: Diagrams JX206
Splice Pack Connector End Views
JX206
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Branching Point > Component
Information > Diagrams > JX205 > Page 14860
Branching Point: Diagrams JX207
Splice Pack Connector End Views
JX207
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams
Circuit Breaker: Diagrams
Component Connector End Views
Circuit Breaker 1 (SEO 9C1/9C3)
Circuit Breaker 2 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Diagrams > Page 14864
Circuit Breaker 3 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14873
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14879
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer Inoperative/Poor
Performance
Fuse: Customer Interest Wipers/Washers - Washer Inoperative/Poor Performance
Bulletin No.: 07-08-43-004C
Date: November 19, 2007
TECHNICAL
Subject: EI07089 - Windshield Washer Inoperative, Poor Performance (Replace WSW Fuse)
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Supercede:
This bulletin is being revised to include 2008 Impala. Please discard Corporate Bulletin Number
07-08-43-004B (Section 08 - Body and Accessories).
Condition
Some customer's may comment that the windshield washer pump operation is intermittent.
Correction
DO NOT REPLACE THE WINDSHIELD WASHER PUMP.
Engineering has determined that windshield washer pump intermittent operation or poor
performance conditions may be corrected by replacing the current 10 amp WSW fuse with a 15
amp fuse. The WSW (windshield washer) fuse is located in the UBEC (underhood bussed electrical
center).
Be sure to update the UBEC fuse label to indicate the use of a 15 amp fuse for the Windshield
Washer (WSW).
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer Inoperative/Poor
Performance > Page 14888
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer
Inoperative/Poor Performance
Fuse: All Technical Service Bulletins Wipers/Washers - Washer Inoperative/Poor Performance
Bulletin No.: 07-08-43-004C
Date: November 19, 2007
TECHNICAL
Subject: EI07089 - Windshield Washer Inoperative, Poor Performance (Replace WSW Fuse)
Models: 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala
Supercede:
This bulletin is being revised to include 2008 Impala. Please discard Corporate Bulletin Number
07-08-43-004B (Section 08 - Body and Accessories).
Condition
Some customer's may comment that the windshield washer pump operation is intermittent.
Correction
DO NOT REPLACE THE WINDSHIELD WASHER PUMP.
Engineering has determined that windshield washer pump intermittent operation or poor
performance conditions may be corrected by replacing the current 10 amp WSW fuse with a 15
amp fuse. The WSW (windshield washer) fuse is located in the UBEC (underhood bussed electrical
center).
Be sure to update the UBEC fuse label to indicate the use of a 15 amp fuse for the Windshield
Washer (WSW).
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 07-08-43-004C > Nov > 07 > Wipers/Washers - Washer
Inoperative/Poor Performance > Page 14894
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse
Warning
Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuse: > 08-08-64-014 > Aug > 08 > A/C - Windows Fog Up With
Blower Motor ON
Cowl: All Technical Service Bulletins A/C - Windows Fog Up With Blower Motor ON
TECHNICAL
Bulletin No.: 08-08-64-014
Date: August 22, 2008
Subject: Windows Fog Up When HVAC Blower Is Turned Up (Install Water Preventative Filter In
Plenum Area)
Models: 2006-2008 Chevrolet Impala
Built Prior to 5/1/08
Condition
Some customers may comment that the windows fog up when the HVAC blower speed is
increased.
Cause
This condition may be caused by water from the drain hole under the plenum area getting drawn
into the HVAC system.
Correction
Important:
DO NOT replace any HVAC components.
Technicians are to install a water preventative filter in the plenum area using the procedure below.
1. Set the windshield wiper arms so they are not in the park position (half way preferably).
2. Remove the left air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in SI.
3. Remove the plenum water deflector.
4. Assemble the bolt (1), clip (2) and filter (3) as shown.
5. Install the filter and secure the clip (1) as shown.
6. Tighten the bolt.
7. Reinstall the plenum water deflector and the air inlet grille.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuse: > 08-08-64-014 > Aug > 08 > A/C - Windows Fog Up With
Blower Motor ON > Page 14904
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuse: > 08-08-64-014 > Aug > 08 > A/C - Windows Fog Up With
Blower Motor ON > Page 14910
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Instrument Panel Fuse Block
Fuse: Locations Instrument Panel Fuse Block
INSTRUMENT PANEL FUSE BLOCK
The fuse block is located on the passenger side of the vehicle in the carpet molding. Remove the
fuse block door to access the fuses.
FUSES .................................................................................................................................................
...................................................................... USAGE
PWR/SEAT ..........................................................................................................................................
.......................................................... Power Seats PWR/WNDW .......................................................
..................................................................................................................................... Power Window
RAP .....................................................................................................................................................
.................................... Retained Accessory Power HTD/SEAT ..........................................................
.......................................................................................................................................... Heated
Seats AUX ...........................................................................................................................................
............................................................ Auxiliary Outlets AMP .............................................................
......................................................................................................................................................
Amplifier S/ROOF ................................................................................................................................
................................................................................ Sunroof XM .........................................................
...........................................................................................................................................................
XM Radio CNSTR ...............................................................................................................................
.................................................................................. Canister DR/LCK ..............................................
............................................................................................................................................................
Door Locks
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PWR/MIR .............................................................................................................................................
...................................................... Power Mirrors AIRBAG .................................................................
............................................................................................................................................... Airbags
TRUNK ................................................................................................................................................
.................................................................... Trunk TRUNK .................................................................
......................................................................................................................................... Trunk Relay
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Locations > Instrument Panel Fuse Block > Page 14914
Fuse: Locations I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P - Label
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Locations > Instrument Panel Fuse Block > Page 14915
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Locations > Instrument Panel Fuse Block > Page 14916
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Locations > Instrument Panel Fuse Block > Page 14917
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Locations > Instrument Panel Fuse Block > Page 14918
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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Diagrams > Diagram Information and Instructions > Page 14935
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Diagrams > Diagram Information and Instructions > Page 14936
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Diagrams > Diagram Information and Instructions > Page 14940
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Diagrams > Diagram Information and Instructions > Page 14948
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuse: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagrams > Diagram Information and Instructions > Page 14951
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagrams > Diagram Information and Instructions > Page 14953
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Application and ID > Underhood Fuse Block
Fuse: Application and ID Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuse: Application and ID I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P - Label
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations > Instrument Panel/Center Console Component Views
Fuse Block: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel Harness - Rear of the Instrument Panel Carrier
1 - J282 2 - J203 3 - J239 4 - J250 5 - J218 6 - Instrument Panel Carrier 7 - J259 8 - J269 9 - Fuse
Block - Auxiliary
Right Front of the Passenger Compartment
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1 - Dash Panel 2 - Fuse Block - Instrument Panel 3 - X303 4 - G302
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Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Battery Attachments (LZE/LZ4/LZ8)
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1 - G102 2 - X105 3 - Fuse Block - Underhood Positive Battery Cable Terminal 4 - Battery 5 Battery Current Sensor
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Fuse Block: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
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General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information > Diagrams > Diagram Information and Instructions > Page 15191
Fuse Block: Connector Views
Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood - Top View
Fuse Block - Underhood - Bottom View
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Fuse Block - Underhood X1
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Fuse Block - Underhood X2
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Fuse Block - Underhood X3
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Fuse Block - Underhood X4
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I/P Fuse Block
Electrical Center Identification Views
Fuse Block - I/P Top View
Fuse Block - I/P X1
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Fuse Block - I/P X2
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 15202
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
- Right Side (Impala)
Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
> Page 15205
Fuse Block: Service and Repair Accessory Wiring Junction Block Replacement
Accessory Wiring Junction Block Replacement
Removal Procedure
1. Remove the electrical center cover (1). 2. Disconnect the positive battery cable from junction
box.
3. Remove the fasteners (1) securing the electrical center board (2). 4. Unlock the tabs on the
electrical center board. 5. Lift up on the electrical center board.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
> Page 15206
6. Remove the fasteners (1) securing the electrical center bracket (2) to vehicle.
Installation Procedure
Notice: Refer to Fastener Notice.
1. Install fasteners (1) securing the electrical center (2) to vehicle.
Tighten the fasteners to 10 N.m (86 lb in).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement - Right Side (Impala)
> Page 15207
2. Install the fasteners (1) securing the electrical center board (2).
Tighten the fasteners to 7 N.m (62 lb in).
3. Connect the positive battery cable.
4. Install the electrical center cover (1).
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair
Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15212
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15213
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15214
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15215
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15216
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 15217
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 15226
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 09-08-49-005
> Mar > 09 > Instruments - Inaccurate Fuel Gauge Readings
Multiple Junction Connector: Customer Interest Instruments - Inaccurate Fuel Gauge Readings
TECHNICAL
Bulletin No.:09-08-49-005
Date: March 27, 2009
Subject: Fuel Gage Reads Inaccurate or Empty, Low Fuel Indicator Illuminated, DTCs P0461
and/or P0463 Set (Check Terminals in Connector X405)
Models: 2008-2009 Buick Allure (Canada Only), Allure Super (Canada Only), LaCrosse, LaCrosse
Super 2008-2009 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the low fuel indicator comes on and the fuel gage reads empty
when there is fuel in the tank. Other comments may be that the fuel gage is inaccurate.
Upon further inspection, it may be found that DTC P0461 and/or P0463 have been set.
Cause
This condition may be due to poor terminal tension at connector X405, resulting in resistance at the
affected circuits.
Correction
Perform a pin drag test on all female terminals within connector X405. If a terminal is found to be
loose or have poor tension, replace the affected terminal.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC
P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 15236
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
09-08-49-005 > Mar > 09 > Instruments - Inaccurate Fuel Gauge Readings
Multiple Junction Connector: All Technical Service Bulletins Instruments - Inaccurate Fuel Gauge
Readings
TECHNICAL
Bulletin No.:09-08-49-005
Date: March 27, 2009
Subject: Fuel Gage Reads Inaccurate or Empty, Low Fuel Indicator Illuminated, DTCs P0461
and/or P0463 Set (Check Terminals in Connector X405)
Models: 2008-2009 Buick Allure (Canada Only), Allure Super (Canada Only), LaCrosse, LaCrosse
Super 2008-2009 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the low fuel indicator comes on and the fuel gage reads empty
when there is fuel in the tank. Other comments may be that the fuel gage is inaccurate.
Upon further inspection, it may be found that DTC P0461 and/or P0463 have been set.
Cause
This condition may be due to poor terminal tension at connector X405, resulting in resistance at the
affected circuits.
Correction
Perform a pin drag test on all female terminals within connector X405. If a terminal is found to be
loose or have poor tension, replace the affected terminal.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199
Multiple Junction Connector: Diagrams X100 - X199
X100
Inline Harness Connector End Views
X100 Engine Harness to Transmission Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15243
X101
Inline Harness Connector End Views
X101 I/P Harness to Engine Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15244
X105
Inline Harness Connector End Views
X105 Battery Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15245
X107
Inline Harness Connector End Views
X107 Engine Harness to Front Ignition Coil Harness (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15246
X108
Inline Harness Connector End Views
X108 Engine Harness to Rear Ignition Coil Harness (LS4)
X111
Inline Harness Connector End Views
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15247
X111 I/P Harness to Engine Harness
X116
Inline Harness Connector End Views
X116 Crankshaft/Knock Sensor Jumper Harness to Engine Harness (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15248
X120
Inline Harness Connector End Views
X120 I/P Harness to Forward Lamp Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15249
X122
Inline Harness Connector End Views
X122 Forward Lamp Harness to Forward Lamp Harness (9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15250
X123
Inline Harness Connector End Views
X123 I/P Harness to the Grille Lamp Jumper Harness (6J3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15251
X141
Inline Harness Connector End Views
X141 Forward Lamp Harness to Left Front Headlamp Assembly Harness
X142
Inline Harness Connector End Views
X142 Forward Lamp Harness to Right Front Headlamp Assembly Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15252
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15253
Multiple Junction Connector: Diagrams X200 - X299
X200
Inline Harness Connector End Views
X200 Body Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15254
X200 Body Harness To I/P Harness (Pin A1 To C8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15255
X200 Body Harness To I/P Harness (Pin C9 To D8)
X201
Inline Harness Connector End Views
X201 Steering Column Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15256
X203
Inline Harness Connector End Views
X203 I/P Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15257
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15258
X203 I/P Harness To Body Harness (Pin A1 To C4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15259
X203 I/P Harness To Body Harness (Pin C5 To D8)
X208
Inline Harness Connector End Views
X208 SEO Auxiliary Harness to Body Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15260
X210
Inline Harness Connector End Views
X210 I/P Harness to HVAC Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15261
X223
Inline Harness Connector End Views
X223 Body Harness to Body Harness (9C1, 9C3)
X250
Inline Harness Connector End Views
X250 SIR Coil to the Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15262
X266
Inline Harness Connector End Views
X266 I/P Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15263
X267
Inline Harness Connector End Views
X267 I/P Harness to I/P Harness(9C1, 9C3, without WX7)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15264
X267A
Inline Harness Connector End Views
X267A I/P Harness to I/P Harness (9C1, 9C3, with WX7)
X267B
Inline Harness Connector End Views
X267B I/P Harness to I/P Harness (9C1, 9C3, with WX7)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15265
X275
Inline Harness Connector End Views
X275 SIR Coil to Steering Column Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15266
X277
Inline Harness Connector End Views
X277 SIR Coil to Steering Wheel Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15267
X278
Inline Harness Connector End Views
X278 Inflatable Restraint I/P Module Jumper Harness to the Body Harness
X297
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15268
Inline Harness Connector End Views
X297 I/P Harness to Grille Lamp Jumper Harness (9C1, 9C3, 6J3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15269
Multiple Junction Connector: Diagrams X300 - X399
X301
Inline Harness Connector End Views
X301 Body Harness to Left Front Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15270
X301 Body Harness To Left Front Door Harness (Pin A1 To D3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15271
X301 Body Harness To Left Front Door Harness (Pin D4 To D8)
X302
Inline Harness Connector End Views
X302 Body Harness to Right Front Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15272
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15273
X302 Body Harness To Right Front Door Harness (Pin A1 To D6)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15274
X302 Body Harness To Right Front Door Harness (Pin D7 To D8)
X311
Inline Harness Connector End Views
X311 Body Harness to Left Front Seat Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15275
X313
Inline Harness Connector End Views
X313 Body Harness to Right Front Seat Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15276
X322
Inline Harness Connector End Views
X322 Body Harness to Roof Wiring Provision Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15277
X340
Inline Harness Connector End Views
X340 Console Harness to Body Harness (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15278
X340 Console Harness to Body Harness (Floor Console)
X355
Inline Harness Connector End Views
X355 Body Harness to Left Rear Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15279
X356
Inline Harness Connector End Views
X356 Body Harness to Right Rear Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15280
X360
Inline Harness Connector End Views
X360 Body Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15281
X362
Inline Harness Connector End Views
X362 Body Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15282
X398
Inline Harness Connector End Views
X398 Roof Harness to Sunroof Harness (CF5)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15283
Multiple Junction Connector: Diagrams X400 - X499
X401
Inline Harness Connector End Views
X401 Rear Body Harness to Left Tail Lamp Harness
X402
Inline Harness Connector End Views
X402 Rear Body Harness to Right Tail Lamp Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15284
X405
Inline Harness Connector End Views
X405 Rear Chassis Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15285
X406
Inline Harness Connector End Views
X406 Body Harness to Rear Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15286
X409
Inline Harness Connector End Views
X409 Emergency Vehicle Rear Compartment Lid Lamps Harness to Body Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15287
X412
Inline Harness Connector End Views
X412 Roof Rail Module - Left Jumper Harness to Body Harness (AY1)
X414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15288
Inline Harness Connector End Views
X414 Roof Rail Module - Right Jumper Harness to Body Harness (AY1)
X490
Inline Harness Connector End Views
X490 Roof Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15289
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15290
Multiple Junction Connector: Diagrams
X100
Inline Harness Connector End Views
X100 Engine Harness to Transmission Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15291
X101
Inline Harness Connector End Views
X101 I/P Harness to Engine Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15292
X105
Inline Harness Connector End Views
X105 Battery Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15293
X107
Inline Harness Connector End Views
X107 Engine Harness to Front Ignition Coil Harness (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15294
X108
Inline Harness Connector End Views
X108 Engine Harness to Rear Ignition Coil Harness (LS4)
X111
Inline Harness Connector End Views
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15295
X111 I/P Harness to Engine Harness
X116
Inline Harness Connector End Views
X116 Crankshaft/Knock Sensor Jumper Harness to Engine Harness (LS4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15296
X120
Inline Harness Connector End Views
X120 I/P Harness to Forward Lamp Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15297
X122
Inline Harness Connector End Views
X122 Forward Lamp Harness to Forward Lamp Harness (9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15298
X123
Inline Harness Connector End Views
X123 I/P Harness to the Grille Lamp Jumper Harness (6J3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15299
X141
Inline Harness Connector End Views
X141 Forward Lamp Harness to Left Front Headlamp Assembly Harness
X142
Inline Harness Connector End Views
X142 Forward Lamp Harness to Right Front Headlamp Assembly Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15300
X200
Inline Harness Connector End Views
X200 Body Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15301
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15302
X200 Body Harness To I/P Harness (Pin A1 To C8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15303
X200 Body Harness To I/P Harness (Pin C9 To D8)
X201
Inline Harness Connector End Views
X201 Steering Column Harness to I/P Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15304
X203
Inline Harness Connector End Views
X203 I/P Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15305
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15306
X203 I/P Harness To Body Harness (Pin A1 To C4)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15307
X203 I/P Harness To Body Harness (Pin C5 To D8)
X208
Inline Harness Connector End Views
X208 SEO Auxiliary Harness to Body Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15308
X210
Inline Harness Connector End Views
X210 I/P Harness to HVAC Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15309
X223
Inline Harness Connector End Views
X223 Body Harness to Body Harness (9C1, 9C3)
X250
Inline Harness Connector End Views
X250 SIR Coil to the Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15310
X266
Inline Harness Connector End Views
X266 I/P Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15311
X267
Inline Harness Connector End Views
X267 I/P Harness to I/P Harness(9C1, 9C3, without WX7)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15312
X267A
Inline Harness Connector End Views
X267A I/P Harness to I/P Harness (9C1, 9C3, with WX7)
X267B
Inline Harness Connector End Views
X267B I/P Harness to I/P Harness (9C1, 9C3, with WX7)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15313
X275
Inline Harness Connector End Views
X275 SIR Coil to Steering Column Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15314
X277
Inline Harness Connector End Views
X277 SIR Coil to Steering Wheel Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15315
X278
Inline Harness Connector End Views
X278 Inflatable Restraint I/P Module Jumper Harness to the Body Harness
X297
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15316
Inline Harness Connector End Views
X297 I/P Harness to Grille Lamp Jumper Harness (9C1, 9C3, 6J3)
X301
Inline Harness Connector End Views
X301 Body Harness to Left Front Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15317
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15318
X301 Body Harness To Left Front Door Harness (Pin A1 To D3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15319
X301 Body Harness To Left Front Door Harness (Pin D4 To D8)
X302
Inline Harness Connector End Views
X302 Body Harness to Right Front Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15320
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15321
X302 Body Harness To Right Front Door Harness (Pin A1 To D6)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15322
X302 Body Harness To Right Front Door Harness (Pin D7 To D8)
X311
Inline Harness Connector End Views
X311 Body Harness to Left Front Seat Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15323
X313
Inline Harness Connector End Views
X313 Body Harness to Right Front Seat Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15324
X322
Inline Harness Connector End Views
X322 Body Harness to Roof Wiring Provision Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15325
X340
Inline Harness Connector End Views
X340 Console Harness to Body Harness (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15326
X340 Console Harness to Body Harness (Floor Console)
X355
Inline Harness Connector End Views
X355 Body Harness to Left Rear Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15327
X356
Inline Harness Connector End Views
X356 Body Harness to Right Rear Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15328
X360
Inline Harness Connector End Views
X360 Body Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15329
X362
Inline Harness Connector End Views
X362 Body Harness to I/P Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15330
X398
Inline Harness Connector End Views
X398 Roof Harness to Sunroof Harness (CF5)
X401
Inline Harness Connector End Views
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15331
X401 Rear Body Harness to Left Tail Lamp Harness
X402
Inline Harness Connector End Views
X402 Rear Body Harness to Right Tail Lamp Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15332
X405
Inline Harness Connector End Views
X405 Rear Chassis Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15333
X406
Inline Harness Connector End Views
X406 Body Harness to Rear Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15334
X409
Inline Harness Connector End Views
X409 Emergency Vehicle Rear Compartment Lid Lamps Harness to Body Harness (9C1, 9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15335
X412
Inline Harness Connector End Views
X412 Roof Rail Module - Left Jumper Harness to Body Harness (AY1)
X414
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15336
Inline Harness Connector End Views
X414 Roof Rail Module - Right Jumper Harness to Body Harness (AY1)
X490
Inline Harness Connector End Views
X490 Roof Harness to Body Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15337
X500 - X599
Inline Harness Connector End Views
X503 Left Front Door Harness to Left Front Door Trim Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15338
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15339
X503 Left Front Door Harness To Left Front Door Trim Harness (Pin A1 To D6)
X503 Left Front Door Harness To Left Front Door Trim Harness (Pin D7 To D8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 15340
X600 - X699
Inline Harness Connector End Views
X604 Right Front Door Trim Harness to Right Front Door Harness
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 15345
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 15346
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 15355
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 15356
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules
Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 15365
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 15366
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 15367
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power
Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power > Page 15372
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-08-49-005 > Mar > 09 > Instruments - Inaccurate Fuel
Gauge Readings
Wiring Harness: Customer Interest Instruments - Inaccurate Fuel Gauge Readings
TECHNICAL
Bulletin No.:09-08-49-005
Date: March 27, 2009
Subject: Fuel Gage Reads Inaccurate or Empty, Low Fuel Indicator Illuminated, DTCs P0461
and/or P0463 Set (Check Terminals in Connector X405)
Models: 2008-2009 Buick Allure (Canada Only), Allure Super (Canada Only), LaCrosse, LaCrosse
Super 2008-2009 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the low fuel indicator comes on and the fuel gage reads empty
when there is fuel in the tank. Other comments may be that the fuel gage is inaccurate.
Upon further inspection, it may be found that DTC P0461 and/or P0463 have been set.
Cause
This condition may be due to poor terminal tension at connector X405, resulting in resistance at the
affected circuits.
Correction
Perform a pin drag test on all female terminals within connector X405. If a terminal is found to be
loose or have poor tension, replace the affected terminal.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 08-06-04-039 > Aug > 08 > Electrical/Fuel Systems - Crank
But No Start
Wiring Harness: Customer Interest Electrical/Fuel Systems - Crank But No Start
TECHNICAL
Bulletin No.: 08-06-04-039
Date: August 07, 2008
Subject: Crank/No Start, Blown Fuel Pump Fuse (Replace Fuse and Repair Wiring Harness)
Models: 2006-2008 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the vehicle cranks but does not start.
Cause
The cause of this condition may be due to the fuel pump fuse being blown or open.
Correction
Inspect the wire harness under the rear seat for chafing. The affected wire is circuit 120, gray wire,
between connectors C200 and C405. If wire chafing is found, reroute the harness away from the
area of chafing and repair any damaged circuits per instructions in SI.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 15386
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 15387
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 15388
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15393
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15394
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15395
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15396
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15397
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 15398
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 15403
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-49-005 > Mar > 09 > Instruments Inaccurate Fuel Gauge Readings
Wiring Harness: All Technical Service Bulletins Instruments - Inaccurate Fuel Gauge Readings
TECHNICAL
Bulletin No.:09-08-49-005
Date: March 27, 2009
Subject: Fuel Gage Reads Inaccurate or Empty, Low Fuel Indicator Illuminated, DTCs P0461
and/or P0463 Set (Check Terminals in Connector X405)
Models: 2008-2009 Buick Allure (Canada Only), Allure Super (Canada Only), LaCrosse, LaCrosse
Super 2008-2009 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the low fuel indicator comes on and the fuel gage reads empty
when there is fuel in the tank. Other comments may be that the fuel gage is inaccurate.
Upon further inspection, it may be found that DTC P0461 and/or P0463 have been set.
Cause
This condition may be due to poor terminal tension at connector X405, resulting in resistance at the
affected circuits.
Correction
Perform a pin drag test on all female terminals within connector X405. If a terminal is found to be
loose or have poor tension, replace the affected terminal.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-04-039 > Aug > 08 > Electrical/Fuel
Systems - Crank But No Start
Wiring Harness: All Technical Service Bulletins Electrical/Fuel Systems - Crank But No Start
TECHNICAL
Bulletin No.: 08-06-04-039
Date: August 07, 2008
Subject: Crank/No Start, Blown Fuel Pump Fuse (Replace Fuse and Repair Wiring Harness)
Models: 2006-2008 Chevrolet Impala, Impala SS
Condition
Some customers may comment that the vehicle cranks but does not start.
Cause
The cause of this condition may be due to the fuel pump fuse being blown or open.
Correction
Inspect the wire harness under the rear seat for chafing. The affected wire is circuit 120, gray wire,
between connectors C200 and C405. If wire chafing is found, reroute the harness away from the
area of chafing and repair any damaged circuits per instructions in SI.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-44-008A > Apr > 08 >
Audio System - XM Radio(R) Won't Retain Station Setting
Radio Receiver: All Technical Service Bulletins Audio System - XM Radio(R) Won't Retain Station
Setting
TECHNICAL
Bulletin No.: 08-08-44-008A
Date: April 25, 2008
Subject: XM Radio Does Not Retain Station Setting From Previous Key Cycle and Changes To
Channel 1, The Preview Channel, at Vehicle Start-up (Replace Digital Radio Receiver Assembly)
Models: 2008 Buick Enclave, Lucerne 2008 Cadillac DTS, Escalade Models, SRX 2008 Chevrolet
Avalanche, Equinox, Impala, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia 2008 GMC
Sierra, Yukon Models 2008 Pontiac Torrent 2008 HUMMER H2, H2 SUT 2007-2008 Saturn
OUTLOOK 2008 Saturn VUE 2008 Suzuki XL-7
with XM Satellite Radio (RPO U2K)
Supercede:
This bulletin is being revised to add the Suzuki XL-7 model. Please discard Corporate Bulletin
Number 08-08-44-008 (Section 08 - Body & Accessories).
Condition
Some customers may comment that the XM radio does not retain the station setting from the
previous key cycle and changes to channel 1 at vehicle start-up. After start-up, the XM radio will be
on the preview channel 1.
Cause
A software anomaly in the Digital Radio Receiver Assembly may cause this condition.
Correction
Technicians are to replace the Digital Radio Receiver Assembly with an updated design part. Refer
to the Digital Radio Receiver Replacement procedure in SI. Also refer to the Digital Radio Receiver
Setup procedure in SI for additional information.
Parts Information
Warranty Information
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-44-008A > Apr > 08 >
Audio System - XM Radio(R) Won't Retain Station Setting > Page 15417
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-44-008A > Apr > 08 >
Audio System - XM Radio(R) Won't Retain Station Setting > Page 15423
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Accessory Relay > Component Information > Locations
Accessory Relay: Locations
Electrical Center Identification Views
Fuse Block - I/P - Label
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15432
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Diagrams > Diagram Information and Instructions > Page 15433
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Diagrams > Diagram Information and Instructions > Page 15434
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Diagrams > Diagram Information and Instructions > Page 15435
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Diagrams > Diagram Information and Instructions > Page 15436
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Diagrams > Diagram Information and Instructions > Page 15437
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Diagrams > Diagram Information and Instructions > Page 15438
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Diagrams > Diagram Information and Instructions > Page 15439
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Diagrams > Diagram Information and Instructions > Page 15440
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Diagrams > Diagram Information and Instructions > Page 15441
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Diagrams > Diagram Information and Instructions > Page 15442
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Diagrams > Diagram Information and Instructions > Page 15443
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Diagrams > Diagram Information and Instructions > Page 15444
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Diagrams > Diagram Information and Instructions > Page 15445
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Diagrams > Diagram Information and Instructions > Page 15446
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Diagrams > Diagram Information and Instructions > Page 15447
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Diagrams > Diagram Information and Instructions > Page 15448
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Diagrams > Diagram Information and Instructions > Page 15449
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Diagrams > Diagram Information and Instructions > Page 15450
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Diagrams > Diagram Information and Instructions > Page 15451
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Diagrams > Diagram Information and Instructions > Page 15452
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Diagrams > Diagram Information and Instructions > Page 15453
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Diagrams > Diagram Information and Instructions > Page 15454
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Diagrams > Diagram Information and Instructions > Page 15455
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Diagrams > Diagram Information and Instructions > Page 15456
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Diagrams > Diagram Information and Instructions > Page 15457
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Diagrams > Diagram Information and Instructions > Page 15458
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15459
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15460
Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15461
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15462
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15463
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Special Tools
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15504
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15505
4. Release the lower wire dress cover locking tab.
5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15506
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15507
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15508
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15509
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15510
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15511
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15512
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15513
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15514
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15515
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15516
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15517
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15518
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15519
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15520
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15521
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
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Diagrams > Diagram Information and Instructions > Page 15522
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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Diagrams > Diagram Information and Instructions > Page 15523
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15524
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15525
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Diagrams > Diagram Information and Instructions > Page 15526
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Diagrams > Diagram Information and Instructions > Page 15527
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15528
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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Diagrams > Diagram Information and Instructions > Page 15529
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15530
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15531
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Diagrams > Diagram Information and Instructions > Page 15532
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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Diagrams > Diagram Information and Instructions > Page 15533
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15534
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15535
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15536
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15537
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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Diagrams > Diagram Information and Instructions > Page 15538
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15539
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15540
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15541
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing.
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors
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and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15555
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Diagram Information and Instructions > Page 15556
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product
AL-36FR to replace the damaged mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with electrical tape to replace the outer
insulation.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15557
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15558
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15559
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Accessory Power Outlet - Center Console 1 (with Floor Console)
Accessory Power Outlet - Center Console 2 (with Floor Console)
Accessory Power Outlet - Center Console Compartment (with Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15560
Accessory Power Outlet - Center Seat (without Floor Console)
Accessory Power Outlet - I/P 1 (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Diagram Information and Instructions > Page 15561
Accessory Power Outlet - I/P 2 (without Floor Console)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information >
Diagrams > Page 15562
Auxiliary Power Outlet: Service and Repair
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigar Lighter Socket Remover
Removal Procedure
1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle:
1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the
front of the receptacle. The J 42059 pushes the
plastic latches from these tab windows and the receptacle can be pulled straight out.
2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit
straight into the receptacle. Angle the J 42059
slightly for insertion into the receptacle.
3. Insert the other side of the "T" into the opposite tab window.
You must move the J 42059 handle toward horizontal to engage the other tab window.
4. Use the J 42059 to pull the receptacle straight out.
3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate
method:
1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in
the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket.
Installation Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Page 15563
1. Route the connector through the retainer. Align the accessory power receptacle retainer to the
slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the
electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer.
Install the accessory power receptacle by pressing into place until fully seated. 5. Install the
accessory power receptacle fuse.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagrams > Page 15564
Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Branching Point > Component Information > Diagrams >
JX205
Branching Point: Diagrams JX205
Splice Pack Connector End Views
JX205
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Branching Point > Component Information > Diagrams >
JX205 > Page 15569
Branching Point: Diagrams JX206
Splice Pack Connector End Views
JX206
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Branching Point > Component Information > Diagrams >
JX205 > Page 15570
Branching Point: Diagrams JX207
Splice Pack Connector End Views
JX207
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams
Circuit Breaker: Diagrams
Component Connector End Views
Circuit Breaker 1 (SEO 9C1/9C3)
Circuit Breaker 2 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Page 15574
Circuit Breaker 3 (SEO 9C1/9C3)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R) > Page 15583
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R) > Page 15589
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Instrument Panel/Center Console Component Views
Fuse Block: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel Harness - Rear of the Instrument Panel Carrier
1 - J282 2 - J203 3 - J239 4 - J250 5 - J218 6 - Instrument Panel Carrier 7 - J259 8 - J269 9 - Fuse
Block - Auxiliary
Right Front of the Passenger Compartment
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 15594
1 - Dash Panel 2 - Fuse Block - Instrument Panel 3 - X303 4 - G302
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 15595
Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Battery Attachments (LZE/LZ4/LZ8)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 15596
1 - G102 2 - X105 3 - Fuse Block - Underhood Positive Battery Cable Terminal 4 - Battery 5 Battery Current Sensor
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Instrument Panel/Center Console Component Views > Page 15597
Fuse Block: Locations Powertrain Component Views
Powertrain Component Views
Right Front of the Engine Compartment
1 - Fuse Block - Underhood 2 - Generator 3 - Brake Fluid Level Switch 4 - Battery 5 - Inflatable
Restraint Front End Sensor - Right 6 - G100 7 - Horn Assembly 8 - Windshield Washer Fluid
Container 9 - Windshield Washer Fluid Level Switch 10 - Windshield Washer Fluid Pump 11 Battery Current Sensor 12 - G102
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Electrical Symbols
Electrical Symbols
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
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Diagram Information and Instructions > Page 15600
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Diagram Information and Instructions > Page 15601
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Diagram Information and Instructions > Page 15602
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Diagram Information and Instructions > Page 15603
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Diagram Information and Instructions > Page 15604
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Diagram Information and Instructions > Page 15605
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Diagram Information and Instructions > Page 15606
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Diagram Information and Instructions > Page 15607
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Diagram Information and Instructions > Page 15608
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Diagram Information and Instructions > Page 15609
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Diagram Information and Instructions > Page 15610
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Diagram Information and Instructions > Page 15611
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Diagram Information and Instructions > Page 15612
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Diagram Information and Instructions > Page 15613
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Diagram Information and Instructions > Page 15614
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Diagram Information and Instructions > Page 15615
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Diagram Information and Instructions > Page 15616
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Diagram Information and Instructions > Page 15617
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Diagram Information and Instructions > Page 15618
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Diagram Information and Instructions > Page 15619
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Diagram Information and Instructions > Page 15620
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Diagram Information and Instructions > Page 15621
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Diagram Information and Instructions > Page 15622
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Diagram Information and Instructions > Page 15623
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Diagram Information and Instructions > Page 15624
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Diagram Information and Instructions > Page 15625
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Diagram Information and Instructions > Page 15626
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Diagram Information and Instructions > Page 15627
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the service manual. You should understand the basic theory of electricity, and know
the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to
read and understand a wiring diagram, as well as understand what happens in a circuit with an
open or a shorted wire.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15628
Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This Service Data uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15629
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15630
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15631
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Measuring Voltage Drop
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Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Passenger Car Zoning
Passenger Car Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.0m
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
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J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and
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Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
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- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
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Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
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1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3.5GWhen the bulb illuminates, there is voltage at the point being
tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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Diagram Information and Instructions > Page 15643
3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15644
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15645
7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15646
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15647
4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15648
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15649
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15650
6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15651
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15652
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
Chevrolet Impala Workshop Manual (V8-5.3L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 15653
1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.